Surface cleaning apparatus

ABSTRACT

A surface cleaning apparatus comprises a uniflow cyclone chamber comprising an air inlet in a first end, a dirt outlet in a second end and an air outlet that is configured so that air exits the cyclone chamber through the second end.

FIELD

This specification relates to a surface cleaning apparatus. In apreferred embodiment, the surface cleaning apparatus has a uniflowcyclone with a slot shaped sidewall dirt outlet. In a particularlypreferred embodiment, the surface cleaning apparatus is a portable handcarriable surface cleaning apparatus.

INTRODUCTION

The following is not an admission that anything discussed below is partof the prior art or part of the common general knowledge of a personskilled in the art.

Surface cleaning apparatus which utilize one or more cyclonic cleaningstages are known. Typically, a cyclone has an air inlet and an airoutlet at the same end (e.g., the upper end). Dirt may accumulate in theother end (e.g., the bottom) of the cyclone chamber. Alternately, a dirtoutlet may be provided in the bottom of the cyclone chamber so as toallow separated particulate matter to travel to a dirt collectionchamber that is exterior to the cyclone chamber (see for example, US2009/0205160). See also, US 2011/0314631, which discloses a cyclonechamber having an air inlet and an air outlet at one end and the endwall opposed to the end with the air inlet and the air outlet is spacedfrom the sidewall of the cyclone chamber by a variable amount so as toprovide an outlet through which dirt may exit the cyclone chamber to anexterior dirt collection chamber.

SUMMARY

This summary is intended to introduce the reader to the more detaileddescription that follows and not to limit or define any claimed or asyet unclaimed invention. One or more inventions may reside in anycombination or sub-combination of the elements or process stepsdisclosed in any part of this document including its claims and figures.

According to one broad aspect, a surface cleaning apparatus is providedwith a uniflow cyclone chamber having a sidewall outlet. For example,the cyclone air inlet may be provided at a first end, the air outlet(e.g. vortex finder) may be provided at the second opposed end wall anda dirt outlet may be provided through a sidewall of the cyclone chamberat the second opposed end. For example, the dirt outlet may comprise anopening in the sidewall that extends radially around part of thesidewall of the cyclone chamber. The opening may be provided at the endwall of the cyclone chamber or it may be spaced therefrom (e.g., thesidewall may extend to the second opposed wall except at one locationwhich defines a cut out or slot in the sidewall through which dirt mayexit the cyclone chamber). Alternately, the sidewall may be spaced fromthe second opposed end wall so as to provide a gap (which may have aconstant height or may have a variable height) through which dirt mayexit the cyclone chamber. An advantage of this design is that a cyclonechamber having improved dirt separation efficiency is obtained. Byenhancing the separation efficiency of the cyclone, a second stagecyclone may not be needed. In addition, removing an increased amount ofparticulate matter from the airstream passing through the cyclonechamber reduces the amount of entrained particulate matter which will beconveyed to an optional pre-motor filter, thereby extending the lifetimeof the pre-motor filter before washing or replacement is required.

Optionally, the end wall of the cyclone chamber at the air inlet end maybe rounded. For example, the air inlet end of the cyclone chamber may beshaped similar to a horizontal section through a toroid. Accordingly,the rounded portion may extend towards the opposed second end so as todefine part of the sidewall of the cyclone chamber.

Optionally, in such an embodiment, the air inlet end of the cyclonechamber is openable so as to allow access to the interior of the cyclonechamber. The inner end of the rounded portion may be part of theopenable end wall of the cyclone chamber. For example, the roundedportion may abut a facing edge of the sidewall or it may seat against aninner surface of the sidewall. Such a construction is advantageous as itallows the rounded end wall to be emptied while providing an appropriateseal at the opening end of the cyclone chamber. It will be appreciatedthat, optionally, an exterior dirt collection chamber may be openable atthe same end as a cyclone chamber and, in such a case, it is preferablyopenable concurrently with the cyclone chamber. For example, a commonfloor or end wall may be utilized to close both the cyclone chamber andthe dirt collection chamber. In such a case, the end wall of the dirtcollection chamber and the half toroidal shape of the lower end of thecyclone chamber may be molded as a single piece.

It will be appreciated by a person skilled in the art that any of thefeatures relating to the openable end wall of the cyclone chamberdiscussed herein may not be utilized with the uniflow cycloneconstruction disclosed herein but may be used by itself or with anyother feature disclosed herein.

In accordance with another embodiment, a pre-motor filter is provided.Preferably, the pre-motor filter is provided with a transparent housingon the upstream (dirty) side of the pre-motor filter. The transparenthousing permits a user to see the upstream side of the pre-motor filterand determine when the pre-motor filter may require cleaning.

In another embodiment, the pre-motor filter may be provided in a filterholder and the filter holder may be removable from the surface cleaningapparatus for cleaning or replacement of the pre-motor filter. Thefilter holder may define a chamber in which particulate matter conveyedfrom the cyclone chamber to the pre-motor filter may be stored. This mayinclude particulate matter that is dis-entrained as the air changesdirection to travel through the pre-motor filter and/or particulatematter that is separated from the airflow as the airflow enters thepre-motor filter. For example, the filter holder may comprise a cuphaving a sidewall and an end wall. The pre-motor filter may be placed inthe cup spaced from the end wall with the pre-motor filter abutting thesidewall so as to define a dirt cup chamber between the end wall of thecup and the side of the pre-motor filter facing the end wall. An airconduit (e.g. an extension of the vortex finder) may extend through thefoam into the dirt cup chamber. Accordingly, air exiting the cyclonechamber may travel through the conduit into the dirt cup chamber toreach the upstream side of the pre-motor filter and then travel throughthe pre-motor filter. Dirt may accordingly accumulate on the upstreamside of the premotor filter. Optionally, the conduit may extend into thedirt cup chamber to a height above that of the pre-motor filter suchthat particulate matter may not fall downwardly through the conduit intothe cyclone chamber. In accordance with such an embodiment, the filterholder may be removed from the surface cleaning apparatus and conveyedto a location (e.g. a sink or a garbage can) where the pre-motor filtermay be removed so as to allow access to the dirt cup chamber so it maybe emptied. Alternately, a portion of the dirt cup chamber may beopenable. It will be appreciated that, in such an embodiment, the cup orat least the portion of a cup defining the dirt cup chamber may betransparent so as to allow a user to determine when the filter is dirtyand/or the dirt cup chamber should be emptied.

Alternately, in some embodiments, the pre-motor filter may be positionedwith the upstream side facing upwardly. Air may accordingly exit thecyclone chamber and travel, e.g., laterally through a duct to a positionabove the pre-motor filter. The air may then travel downwardly throughthe pre-motor filter. A sidewall may extend above the top of thepre-motor filter to define a dirt collection area. The portion of theduct or housing containing the pre-motor filter may be openable so as toallow access to the dirt collection area. When it is desired to removedirt which has accumulated on top of the pre-motor filter, the duct orhousing may be opened and the portion of the surface cleaning apparatuscontaining the pre-motor filter may be inverted to allow the dirt to beremoved.

It will be appreciated by a person skilled in the art that any of thefeatures of the pre-motor filter and pre-motor filter holder discussedherein need not be utilized with the uniflow cyclone design disclosedherein but may be used by themselves or in combination with any otherfeature disclosed herein.

In accordance with another embodiment, a pre-motor filter is providedwith a pre-motor filter cleaner. For example, an agitation member may beprovided to impact the pre-motor filter, preferably the upstream sidethereof, so as to loosen dirt of the upstream side. The upstream sidemay then be emptied, e.g., by inverting the pre-motor filter (e.g. apre-motor filter holder containing the premotor filter may be invertedthereby removing particular matter that has been loosened from theupstream side of the premotor filter). It will be appreciated that thisfeature is preferably used with the pre-motor filter dirt cup or dirtcollection area discussed herein.

An advantage of this design is that the required amount of time betweenwashing or replacing the pre-motor filter may be increased since theincrease in back pressure caused by a dirty pre-motor filter may bereduced, particularly if the upstream side of the pre-motor filter facesdownwardly. The cleaning member may be a mechanical orelectro-mechanical member that taps, scrapes or otherwise engages thepre-motor filter to remove surface dirt therefrom. For example, areciprocating motor with a hammer or the like provided on an armextending therefrom may be utilized. The hammer may dislodge dirt fromthe upstream side when it contacts the pre-motor filter. Alternately, aweight, which is suspended on an arm at a position spaced from thepre-motor filter may be provided. Movement of the pre-motor filter maycause the weight to oscillate and engage repeatedly the pre-motor filterthereby assisting in cleaning the upstream side of the pre-motor filter.Alternately, one and more ribs or other scrapers may be providedabutting the upstream side and rotatably mounted so as to scrape theupstream surface thereby removing dirt therefrom.

It will be appreciated by a person skilled in the art that any of thefeatures of the filter cleaning member disclosed herein need not beutilized with the uniflow cyclone design disclosed herein but may beused by itself or in combination with any other feature disclosedherein.

If a pre-motor filter is provided with a pre-motor filter dirt cupholder that receives dirt that accumulates on, or is dislodged from, theupstream side of the pre-motor filter, the surface cleaning apparatusmay be constructed such that the pre-motor filter dirt cup may beemptied when the cyclone chamber and/or a dirt collection chamber incommunication with the cyclone chamber is emptied. Preferably, thepre-motor filter dirt cup, the cyclone chamber and the dirt chamber incommunication with the cyclone chamber are concurrently emptied. Forexample, all three dirt collection areas may have a common floor or wallwhich is openable.

The pre-motor filter dirt cup may comprise a chamber exterior to thecyclone chamber which is in communication with the upstream side of thepre-motor filter via an angled pathway (e.g., a ramp). For example, theupstream side of the pre-motor filter may face the air outlet end of thecyclone chamber so that the air exiting the cyclone chamber travelslinearly to reach the pre-motor filter. An angled wall may be providedunderneath the pre-motor filter and above the cyclone chamber so as todirect dirt to a dirt collection chamber adjacent, e.g., the sidewall ofthe cyclone chamber or the dirt collection chamber in communication withthe cyclone chamber. The dirt cup and the cyclone chamber may have acommon floor which is openable. In an alternate design, the upstreamside of the pre-motor filter may face the vortex finder. A dirtcollection chamber may be provided in an insert extending upwardly fromthe end wall of the cyclone chamber opposed to and facing the vortexfinder. Accordingly, dirt may fall from the upstream side of thepre-motor filter and travel downwardly through the vortex finder to thepre-motor filter dirt collection chamber. In such a case, a filtercleaner as discussed previously may be provided and may engage theupstream side of the pre-motor filter. Accordingly, when a cyclone isnot in use (e.g. the vacuum cleaner is turned off), the filter cleaningmember may tap or otherwise physically agitate the pre-motor filter toloosen dirt which then falls downwardly through the vortex finder intothe dirt collection chamber for the pre-motor filter. It will beappreciated that the dirt collection chamber for the premotor filter maybe opened when the end wall of the cyclone chamber is opened so as topermit the cyclone chamber to be emptied.

It will be appreciated by a person skilled in the art that any of thefeatures of the openable pre-motor filter dirt cup need not be utilizedwith the uniflow cyclone design disclosed herein but may be used byitself or in combination with any other feature disclosed herein.

Alternately, or in addition, it will be appreciated that the pre-motorfilter dirt cup may be removable for emptying. The pre-motor filter dirtcup may be removable by itself, in combination with the cyclone chamber,in combination with the dirt chamber for the cyclone chamber orpreferably, concurrently with both the cyclone chamber and the dirtcollection chamber for the cyclone chamber. In particular, it ispreferred that the dirt cup is removed with both the cyclone chamber andthe dirt collection chamber and that all three are emptied at the sametime. It will be appreciated by a person skilled in the art that any ofthe features of the removable pre-motor filter dirt cup need not beutilized with the uniflow cyclone design disclosed herein but may beused by itself or in combination with any other features disclosedherein.

In another embodiment, the surface cleaning apparatus may include anexpandable hose which is biased to the extended position and is storedin a contracted position in the surface cleaning apparatus. An advantageof this design is that the suction hose may be stored in the surfacecleaning apparatus and may be deployed when needed. For example, thehose may be stored in a compartment which has a hose outlet. One andmore rollers, preferably at least a pair of opposed rollers or drivewheels, may be provided on opposed sides of the hose. The rollers may bemanually and, preferably, electrically operated. Rotation of the rollersin one direction may allow the hose to be withdrawn from the chamber.Rotation of the rollers in the opposite direction may draw the hoseautomatically into the chamber for storage. In an alternate design, aratchet type mechanism may be used. For example, a pair of pivotallymounted arms which are biased to an engagement position may be provided.The arms are positioned so as to contact the hose in an engaged positionand prevent the hose from expanding and being drawn out of the chamber.If it is desired to remove the hose from the chamber, the arms may bemoved to a disengaged position thereby allowing the hose toautomatically extend itself due to the compression of the hose in thechamber. When it is desired to retract the hose into the chamber, thehose may be manually inserted, thereby compressing the hose in thechamber, or a pair of rollers or other motorized means may draw the hoseinto the chamber. It will be appreciated by a person skilled in the artthat any of the features of a hose that is biased to an extendedposition need not be utilized with the uniflow cyclone design asdisclosed herein but may be used by itself or in combination with anyother feature disclosed herein.

In one embodiment, there is provided a surface cleaning apparatuscomprising:

-   -   (a) a body housing a suction motor;    -   (b) a uniflow cyclone chamber comprising a first end having a        first end wall, a second opposed end having a second end wall, a        sidewall, an air inlet in the first end, a dirt outlet in the        second end and an air outlet that is configured so that air        exits the cyclone chamber through the second end;    -   (c) a dirt collection chamber exterior to the cyclone chamber;        and,    -   (d) an air flow path extending from a dirty air inlet to a clean        air outlet and including the suction motor and the cyclone        chamber.

In some embodiments, the cyclone chamber may have a longitudinal axisand the dirt outlet is oriented generally parallel to the longitudinalaxis.

In some embodiments, the sidewall may extend to the second end and thedirt outlet is provided in the sidewall.

In some embodiments, the first end may comprise a lower end.

In some embodiments, the dirt outlet may have a radial extent and mayhave an upstream end and a downstream end based on the direction ofairflow in the cyclone chamber and the upstream end may be located from0-90 degrees downstream from the air inlet.

In some embodiments, the upstream end may be located from 0-45 degreesdownstream from the air inlet.

In some embodiments, the upstream end may be located from 0-15 degreesdownstream from the air inlet.

In some embodiments, the downstream end may be located from 5-150degrees downstream from the upstream end.

In some embodiments, the downstream end may be located from 15-120degrees downstream from the upstream end.

In some embodiments, the downstream end may be located from 35-75degrees downstream from the upstream end.

In some embodiments, the dirt outlet may have a radial extent and mayhave an upstream end and a downstream end based on the direction ofairflow in the cyclone chamber and the downstream end may be locatedfrom 5-150 degrees downstream from the upstream end.

In some embodiments, the downstream end may be located from 15-120degrees downstream from the upstream end.

In some embodiments, the downstream end may be located from 35-75degrees downstream from the upstream end.

In some embodiments, the dirt collection chamber may partially surroundthe cyclone chamber.

In some embodiments, the dirt outlet may have a radial extent and mayhave an upstream end and a downstream end based on the direction ofairflow in the cyclone chamber and the upstream end may be locatedproximate a location at which a sidewall of the dirt collection chamberextends outwardly from the sidewall of the cyclone chamber.

In some embodiments, the dirt collection chamber may partially surroundthe cyclone chamber and the upstream end may be located proximate alocation at which a sidewall of the dirt collection chamber extendsoutwardly from the sidewall of the cyclone chamber.

In some embodiments, the dirt collection chamber may partially surroundthe cyclone chamber and the upstream end may be located proximate alocation at which a sidewall of the dirt collection chamber extendsoutwardly from the sidewall of the cyclone chamber.

In some embodiments, the dirt collection chamber may partially surroundthe cyclone chamber and the upstream end may be located proximate alocation at which a sidewall of the dirt collection chamber extendsoutwardly from the sidewall of the cyclone chamber.

In some embodiments, the dirt collection chamber may surround thecyclone chamber, the dirt outlet may have a radial extent and may havean upstream end and a downstream end based on the direction of airflowin the cyclone chamber and the upstream end may be located from 0-90degrees upstream from a location at which a sidewall of the dirtcollection chamber is closest to the sidewall of the cyclone chamber.

In some embodiments, the upstream end may be located proximate thelocation at which a sidewall of the dirt collection chamber is closestto the sidewall of the cyclone chamber.

It will be appreciated by a person skilled in the art that a surfacecleaning apparatus may embody any one or more of the features containedherein and that the features may be used in any particular combinationor sub-combination.

DRAWINGS

The drawings included herewith are for illustrating various examples ofarticles, methods, and apparatuses of the teaching of the presentspecification and are not intended to limit the scope of what is taughtin any way.

In the drawings:

FIG. 1 is a perspective view of an embodiment of a surface cleaningapparatus;

FIG. 2 is a cross-sectional view of a portion of the surface cleaningapparatus of FIG. 1, taken along line F2-F2 in FIG. 1;

FIG. 3 is a perspective view of a portion of the surface cleaningapparatus of FIG. 1;

FIG. 4 is a cross sectional view taken along line 4F-4F in FIG. 3;

FIG. 5 is a partially exploded perspective view of the surface cleaningapparatus of FIG. 1;

FIG. 6 is a perspective view of a portion of the surface cleaningapparatus of FIG. 1;

FIG. 7 is the perspective view of FIG. 6 with a portion of the chassisportion removed;

FIG. 8 is a front perspective view of a cyclone bin assembly from thesurface cleaning apparatus of FIG. 1;

FIG. 9 is a rear perspective view of a cyclone bin assembly from thesurface cleaning apparatus of FIG. 1;

FIG. 10 is a bottom perspective view of a cyclone bin assembly from thesurface cleaning apparatus of FIG. 1 with the bin open;

FIG. 11 is a perspective cross sectional view taken along line 11F-11Fin FIG. 8;

FIG. 12 is a top perspective view of a cyclone bin assembly from thesurface cleaning apparatus of FIG. 1 with the lid open and the pre-motorfilters removed;

FIG. 13 is a side perspective view taken along line 11F-11F in FIG. 8;

FIG. 14 is a front perspective view of another embodiment of a cyclonebin assembly;

FIG. 15 is a perspective view of an alternate embodiment of a surfacecleaning apparatus;

FIG. 16 is a cross sectional view taken along line F16-F16 in FIG. 15;

FIG. 17 is a schematic representation of an internal suction hosehousing of the surface cleaning apparatus of FIG. 16;

FIG. 18 is a schematic representation of another embodiment of a surfacecleaning apparatus with an internal suction hose housing;

FIG. 19 is a schematic representation of another embodiment of aninternal suction hose housing of a surface cleaning apparatus;

FIG. 20 is a perspective view of another embodiment of a surfacecleaning apparatus;

FIG. 21 is an exploded perspective view of the surface cleaningapparatus of FIG. 20;

FIG. 22 is a schematic representation of the surface cleaning apparatusof FIG. 20;

FIG. 23 is a block diagram of an embodiment of a converter module;

FIG. 24 is a block diagram of another embodiment of a converter module;

FIG. 25 is a perspective view of the surface cleaning apparatus of FIG.1;

FIG. 26 a is a partially exploded perspective view of the surfacecleaning apparatus of FIG. 20;

FIG. 26 b is a schematic diagram of a cord reel control system;

FIG. 26 c is a partially exploded perspective view of the surfacecleaning apparatus of FIG. 20 including a cord reel;

FIG. 26 d is a partially exploded perspective view of an alternateembodiment of the surface cleaning apparatus of FIG. 20 including a cordreel;

FIG. 27 a is a partially exploded front perspective view of anembodiment of a cord reel;

FIGS. 27 b, 27 c, 27 d and 28 a are front perspective views of the cordreel of FIG. 27 a;

FIG. 28 b is a perspective view of an embodiment of a locating member;

FIG. 28 c is a partially exploded front perspective view of the cordreel of FIGS. 27 a, 27 b, 27 c, 27 d and 28 a;

FIG. 29 is a front perspective view of the cord reel of FIGS. 27 a-28 awith a drive module removed;

FIGS. 30-31 are back perspective views of the cord reel of FIGS. 27 a-28a;

FIGS. 32-33 are perspective views of the cord reel of FIGS. 27 a-28 a incombination with a surface cleaning apparatus;

FIGS. 34-36 are front perspective views of another embodiment of asurface cleaning apparatus;

FIG. 37 is a perspective view from the front of another embodiment of asurface cleaning apparatus;

FIG. 38 is another perspective view from the rear of the surfacecleaning apparatus of FIG. 37;

FIG. 39 is a partially exploded perspective view of the surface cleaningapparatus of FIG. 37;

FIG. 40 is a perspective view of a portion of the surface cleaningapparatus of FIG. 37;

FIG. 41 is a cross sectional view of FIG. 40, taken along line 23-23 inFIG. 40;

FIG. 42 is the cross sectional view of FIG. 41 with a bottom door in anopen position;

FIG. 43 is a bottom perspective view of the surface cleaning apparatusof FIG. 37;

FIG. 44 is a cross sectional view of the surface cleaning apparatus ofFIG. 37, taken along line 26-26 in FIG. 37;

FIG. 45 is a cross sectional view taken along line 27-27 in FIG. 37;

FIG. 46 is a perspective view of the surface cleaning apparatus of FIG.19 with a cover open;

FIG. 47 is the perspective view of FIG. 46 with a filter cartridgeremoved;

FIG. 48 is the perspective view of FIG. 47 with a filter removed fromthe filter cartridge;

FIG. 49 is a cross sectional view of a portion of another embodiment ofa surface cleaning apparatus;

FIG. 50 is a cross sectional view of a portion of another embodiment ofa surface cleaning apparatus;

FIG. 51 is the perspective view of FIG. 47 with a different embodimentof a filter cartridge;

FIG. 52 is a cross sectional view of the filter cartridge taken alongline 34-34 in FIG. 51 with the filter cartridge in the surface cleaningapparatus;

FIG. 53 is a cross sectional view of another embodiment of a portion ofa surface cleaning apparatus;

FIG. 54 is a cross sectional view of an alternate configuration of theportion of the surface cleaning apparatus of FIG. 53;

FIG. 55 is a cross sectional view of another embodiment of a portion ofa surface cleaning apparatus; and,

FIG. 56 is a cross sectional view of an alternate configuration of theportion of the surface cleaning apparatus of FIG. 55;

DETAILED DESCRIPTION

Various apparatuses or processes will be described below to provide anexample of an embodiment of each claimed invention. No embodimentdescribed below limits any claimed invention and any claimed inventionmay cover processes or apparatuses that differ from those describedbelow. The claimed inventions are not limited to apparatuses orprocesses having all of the features of any one apparatus or processdescribed below or to features common to multiple or all of theapparatuses described below. It is possible that an apparatus or processdescribed below is not an embodiment of any claimed invention. Anyinvention disclosed in an apparatus or process described below that isnot claimed in this document may be the subject matter of anotherprotective instrument, for example, a continuing patent application, andthe applicants, inventors or owners do not intend to abandon, disclaimor dedicate to the public any such invention by its disclosure in thisdocument.

General Description of a Cannister Vacuum Cleaner

Referring to FIG. 1, a first embodiment of a surface cleaning apparatus1 is shown. In the embodiment shown, the surface cleaning apparatus is acanister-type vacuum cleaner. In alternate embodiments, the surfacecleaning apparatus may be another suitable type of surface cleaningapparatus, such as an upright-style vacuum cleaner, and hand vacuumcleaner, a stick vac, a wet-dry type vacuum cleaner, a carpet extractoror the like.

In the illustrated example, the surface cleaning apparatus 1 includes achassis portion or support structure 2 and a surface cleaning head 3. Asurface cleaning unit 4 is mounted on the chassis portion 2. The surfacecleaning apparatus 1 also has at least one dirty air inlet 5, at leastone clean air outlet 6, and an air flow path or passage extendingtherebetween. In the illustrated example, the air flow path includes atleast one flexible air flow conduit member (such as a hose 7 or otherflexible conduit). Alternatively, the air flow path may be formed fromrigid members.

At least one suction motor and at least one air treatment member arepositioned in the air flow path to separate dirt and other debris fromthe airflow. Preferably, the chassis portion and/or surface cleaningunit include the suction motor, to draw dirty air in through the dirtyair inlet, and the air treatment member to remove dirt or debris fromthe dirty air flow. The air treatment member may be any suitable airtreatment member, including, for example, one or more cyclones, filters,and bags. Preferably at least one air treatment member is providedupstream from the suction motor. Referring to FIGS. 2 and 3, in theillustrated example, the surface cleaning unit includes both the suctionmotor 8, in a motor housing 12 and an air treatment member in the formof a cyclone bin assembly 9. The motor housing can include at least oneremovable or openable door or grill 13 which may allow a user to accessthe interior of the motor housing 12, for example to access the motor 8,a post motor filter (e.g., a HEPA filter) or any other component withinthe housing 12. Preferably, as exemplified in FIG. 10, a cyclone binassembly 9 is provided wherein the cyclone bin assembly comprises acyclone chamber 10 and a dirt collection chamber 11.

Optionally, the surface cleaning unit 4 may be a portable surfacecleaning unit and may be detachable from the chassis portion (FIG. 3).In such embodiments, the surface cleaning unit 4 includes a suctionmotor and is removably mounted to chassis portion 2. For example,chassis portion 2 may be connected to surface cleaning unit 4 by a mountapparatus 14 that allows the surface cleaning unit 4 to be detached fromthe chassis portion 2. Preferably, mount apparatus is has a releaseactuator that is foot operable, such as a foot pedal. The foot pedal maybe lined electrically or mechanically to a surface cleaning unitengagement member, which may comprise one or more engagement membersconfigured to engage and retain surface cleaning unit 4 in position onchassis portion 2. For example, referring to FIGS. 6 and 7, in theillustrated embodiment the mount apparatus 14 includes a foot pedal 145that is connected to rear latch 146 and to front latch 147 via aconnecting rod 148. The rear latch 146 engages a rear slot 149 on thesurface cleaning unit 4, and the front latch 147 engages a correspondingfront slot 150. Stepping on the pedal 145 can disengage both latches146, 147, thereby releasing the surface cleaning unit 4 from the chassisportion 2. The latches 146, 147 and pedal 145 can be biased toward thelatched configuration. Optionally, a cavity 152 for storing an auxiliarycleaning tool 153 may be formed at the interface between the surfacecleaning unit 4 and the chassis 2 and preferably comprises a recess inthe lower surface of the surface cleaning unit 4.

In the embodiment shown, the surface cleaning head 3 includes the dirtyair inlet 5 in the form of a slot or opening formed in a generallydownward facing surface of the surface cleaning head 3. From the dirtyair inlet 5, the air flow path extends through the surface cleaning head3, and through an up flow conduit 16 (FIG. 2) in the chassis portion 2to the surface cleaning unit 4. In the illustrated example, the cleanair outlet 6 is provided in the rear of the surface cleaning unit 4, andis configured to direct the clear air in a generally lateral direction,toward the back of the apparatus 1.

A handle 17 is provided toward the top of the up flow conduit 16 toallow a user to manipulate the surface cleaning head 3. Referring toFIGS. 1 and 3, the up flow conduit 16 extends along an upper axis 18 andis moveably mounted to the surface cleaning head 3. In the illustratedexample, the up flow conduit 16 is pivotally mounted to the surfacecleaning head via a pivot joint 19. The pivot joint 19 may be anysuitable pivot joint. Alternatively, or in addition to being pivotallycoupled to the surface cleaning head, the up flow conduit 16 can also berotatably mounted to the surface cleaning head. In this configuration,the up flow conduit 16 may be rotatable about the upper axis. In thisconfiguration, rotation of the up flow conduit 16 about the upper axismay help steer the surface cleaning head across the floor (or othersurface being cleaned). It will be appreciated that the surface cleaninghead 3 and conduit 16 may be of any design known in the art and the airflow path to the surface cleaning unit 4 may be of any design.

Portable Cleaning Mode

In one aspect of the teachings described herein, which may be used incombination with any one or more other aspects, the vacuum cleaner 1 maybe operable in a variety different functional configurations oroperating modes. The versatility of operating in different operatingmodes may be achieved by permitting the surface cleaning unit to bedetachable from the chassis portion. Alternatively, or in addition,further versatility may be achieved by permitting portions of the vacuumcleaner to be detachable from each other at a plurality of locations inthe chassis portion, and re-connectable to each other in a variety ofcombinations and configurations.

In the example illustrated, mounting the surface cleaning unit 4 on thechassis portion 2 allows the chassis portion 2 to carry the weight ofthe surface cleaning unit 4 and to, e.g., rollingly support the weightusing rear wheels 100 and front wheel 101 (FIG. 2). With the surfacecleaning unit 4 attached, the vacuum cleaner 1 may be operated like atraditional canister-style vacuum cleaner.

Alternatively, in some cleaning situations the user may preferablydetach the surface cleaning unit 4 from the chassis portion 2 and chooseto carry the surface cleaning unit 4 (e.g. by hand or by a strap)separately from the chassis portion 2, while still using the up flowconduit 16 to drivingly maneuver the surface cleaning head 3. When thesurface cleaning unit 4 is detached, a user may more easily maneuver thesurface cleaning head and the cleaning unit 4 around obstacles, likefurniture and stairs.

To enable the vacuum suction generated by the surface cleaning unit 4 toreach the surface cleaning head 3 when the surface cleaning unit 4 isdetached from the support structure 2, the airflow connection betweenthe surface cleaning head 3 and the cleaning unit 4 is preferably atleast partially formed by a flexible conduit, such as the flexible hose7. The flexible conduit is preferably attached to the surface cleaningunit 4 and not chassis 2 so as to allow a user to detach the surfacecleaning unit 4 and maintain a flow connection between the portablesurface cleaning unit 4 and the surface cleaning head 3 without havingto reconfigure or reconnect any portions of the airflow conduit 16 (FIG.5).

Referring to FIG. 5, when the surface cleaning apparatus 1 is in use, auser may detach the surface cleaning unit 4 from the chassis portion 2without interrupting the airflow communication between the cleaning unit4 and the surface cleaning head 3. This allows a user to selectivelydetach and re-attach the cleaning unit 4 to the support structure 2during use without having to stop and reconfigure the connecting hoses 7or other portions of the airflow conduit 16.

Removable Cyclone Bin Assembly

The following is a description of a removable cyclone bin assembly thatmay be used by itself in any surface cleaning apparatus or in anycombination or sub-combination with any other feature or featuresdisclosed herein.

Optionally, the cyclone bin assembly 9 can be detachable from the motorhousing 12. Providing a detachable cyclone bin assembly 9 may allow auser to carry the cyclone bin assembly 9 to a garbage can for emptying,without needing to carry or move the rest of the surface cleaningapparatus 1. Preferably, the cyclone bin assembly 9 can be separatedfrom the motor housing 12 while the surface cleaning unit 4 is mountedon the chassis portion 2 and also when the surface cleaning unit 4 isseparated from the chassis portion 2. Accordingly, the cyclone binassembly is preferably positioned on an upper portion of the surfacecleaning unit 4 and may be mounted on a shelf or recess providedforwardly of the suction motor.

Preferably, as exemplified in FIG. 3, the cyclone bin assembly 9 isremovable as a closed module, which may help prevent dirt and debrisfrom spilling out of the cyclone bin assembly 9 during transport.

In the illustrated example, the cyclone bin assembly 9 includes an outersidewall 35 and a lid 36. The lid 36 is openable, and in the illustratedembodiment is pivotally connected to the sidewall 35 by hinges 102 (FIG.9) and pivotal between an open position (FIG. 12) and a closed position(FIG. 9). The lid 36 can be held in its closed position using anysuitable closure member, such as releasable latch 103.

In the illustrated embodiment, a bin handle 37 is provided on the lid36. The bin handle 37 may allow a user to carry the surface cleaningunit 4 when it is detached from the chassis portion 2, and preferably isremovable from the suction motor housing 12 with the cyclone binassembly 9 so that it can also be used to carry the cyclone bin assemblyfor emptying.

Cyclone Construction

The following is a description of a cyclone construction that may beused by itself in any surface cleaning apparatus or in any combinationor sub-combination with any other feature or features disclosed herein.

Referring to FIGS. 11 and 13 in the illustrated embodiment the cyclonechamber 10 extends along a cyclone axis 38 and includes a first end wall39, a second end wall 40 axially spaced apart from the first end wall 39and a generally cylindrical sidewall 41 extending between the first andsecond end walls 39, 40. Optionally, some or all of the cyclone wallscan coincide with portions of the dirt collection chamber 11 walls,suction motor housing 12 walls and/or may form portions of the outersurface 35 of surface cleaning unit. Alternatively, in some examplessome or all of the cyclone walls can be distinct from other portions ofthe surface cleaning unit. In the illustrated embodiment, the cyclonechamber 10 is arranged in a generally vertical, uniflow cycloneconfiguration. Alternatively, the cyclone chamber can be provided inanother configuration, including, having at least one or both of the airinlet and air outlet positioned toward the top of the cyclone chamber,or as a horizontal or inclined cyclone.

In the illustrated embodiment, the cyclone chamber 10 includes a cycloneair inlet 42 in fluid communication with a cyclone air outlet 43. Thecyclone chamber 10 also includes at least one dirt outlet 44 (see alsoFIG. 10), through which dirt and debris that is separated from the airflow can exit the cyclone chamber 10. While it is preferred that most orall of the dirt exit the cyclone chamber via the dirt outlet, some dirtmay settle on the bottom end wall 40 of the cyclone chamber 10 and/ormay be carried with the air exiting the cyclone chamber via the airoutlet 43.

Preferably the cyclone air inlet 42 is located toward one end of thecyclone chamber 10 (the lower end in the example illustrated) and may bepositioned adjacent the corresponding cyclone chamber end wall 40.Alternatively, the cyclone air inlet 42 may be provided at anotherlocation within the cyclone chamber 10.

Referring to FIG. 11, in the illustrated embodiment the air inlet 42includes an upstream or inlet end 45, which may be coupled to the hose 7or other suitable conduit, and a downstream end 46 (FIG. 10) that isspaced apart from the upstream end 45. In the illustrated configuration,the cyclone bin assembly 9 can be removed from the surface cleaning unit4, for example, for cleaning or emptying, while the hose 7 remains withthe surface cleaning unit 4. This may allow a user to remove the cyclonebin 9 assembly without having to detach or decouple the hose 7.Alternatively, the downstream end of the hose 7 may be coupled to thecyclone bin assembly 9 such that the downstream end of the hose travelswith the cyclone bin assembly when it is removed.

The air inlet 42 defines an inlet axis 47 and has an inlet diameter 48(FIG. 13). The cross-sectional area of the air inlet 42 taken in a planeorthogonal to the inlet axis 47 can be referred to as thecross-sectional area or flow area of the air inlet 42. Preferably, theair inlet 42 is positioned so that air flowing out of the downstream endis travelling generally tangentially relative to the sidewall 41 of thecyclone chamber 10.

The perimeter of the air inlet 42 defines a cross-sectional shape of theair inlet. The cross-sectional shape of the air inlet can be anysuitable shape. In the illustrated example the air inlet has a generallyround/circular cross-sectional shape with radius 48. Optionally, thediameter 48 may be between about 0.25 inches and about 5 inches or more,preferably between about 1 inch and about 5 inches, more preferably isbetween about 0.75 and 2 inches or between about 1.5 inches and about 3inches, and most preferably is about 2 to 2.5 inches or between about 1to 1.5 inches. Alternatively, instead of being circular, thecross-sectional shape of the air inlet may be another shape, including,for example, oval, square and rectangular.

Air can exit the cyclone chamber 10 via the air outlet 43. Optionally,the cyclone air outlet 43 may be positioned in one of the cyclonechamber end walls, and in the example illustrated is positioned in theend wall 39, at the opposite end of the cyclone chamber 10 from the airinlet 42. In this configuration, air can enter at the bottom of thecyclone chamber 10 and exit at the upper end of the cyclone chamber 10.

In the illustrated example, the cyclone air outlet 43 includes a vortexfinder 49. In the example illustrated, the longitudinal cyclone axis 38is aligned with the orientation of the vortex finder 49. In theillustrated embodiment the air outlet 43 is generally circular incross-sectional shape and defines an air outlet diameter 51 (FIG. 21).Optionally, the cross-sectional or flow area of the cyclone air outlet43 may be between about 50% and about 150% and between about 60%-90% andabout 70%-80% of the cross-sectional area of the cyclone air inlet 42,and preferable is generally equal to the cyclone air inlet area. In thisconfiguration, the air outlet diameter 51 may be about the same as theair inlet diameter 48.

Referring to FIG. 11, in the illustrated embodiment, the upper end wall39 is connected to the upper end of the sidewall 41 to enclose the upperend of the cyclone chamber 10. In the illustrated example, theintersection or juncture 64 between the end wall 39 and the side wall 41is a relatively sharp corner that does not include any type of angled orradiused surface. Similarly, in the illustrated embodiment, the lowerend wall 40 meets the lower end of the cyclone sidewall 41 at a juncture65 that is also configured as a relatively sharp corner.

Optionally, the juncture between the vortex finder 49 and the end wall39 may be provided with an angled or curved surface. In the illustratedembodiment, the juncture 70 between the end wall 40 and the vortexfinder 49 includes a curved surface 72 (FIG. 13). The curved surface 72has a radius 71. The radius 71 may be selected based on the radius ofthe air inlet 42 (e.g. half of the diameter 48), and optionally may bethe selected so that the juncture surface 72 has the same radius as theair inlet 42. Providing curved surface 72 at the juncture 70 may helpreduce backpressure and may help improve cyclone efficiency.

Referring to FIG. 11, in the illustrated embodiment the cyclone is auniflow cyclone and an extension member 77 extends inwardly from a lowerend wall of the cyclone chamber and may extend to a position that isproximate the lower end 105 of the screen 50 and may abut lower end 105.The extension member 77 may be a closed member or, alternately, it maybe a generally hollow tube-like member that extends between the lowerend 105 of the screen 50 and the end wall 40 so as to provide apre-motor filter dirt cup as discussed subsequently. Together, thevortex finder 49, screen 50 and extension member 77 may form a generallycontinuous internal column member that extends between the first andsecond end walls 39 and 40 of the cyclone chamber 10. Providing theprojection member 77 may help direct air flow within the cyclonechamber, and may help support and/or stabilize the distal end 78 of thescreen 50.

Optionally, the juncture 79 between the end wall 40 and the projectionmember 77 may include a curved or angled juncture surface, similar tosurface 72, or may be provided as a sharp corner as illustrated.

In the illustrated embodiment the extension member 77 is integral withthe screen 50 and vortex finder 49, and remains within the cyclonechamber 10 when the door 63 is opened. Alternatively, some or all of theextension member 77, screen 50 and vortex finder 49 may be mounted tothe end wall 40, such that they move with the door 63 and is removedfrom the cyclone chamber 10 when the door 63 is opened.

In the illustrated embodiment, the air inlet 42 is positioned at thejuncture 65 between the sidewall 41 and the end wall 40 and ispositioned such that the air inlet 42 is adjacent the sidewall 41 andthe end wall 40 (i.e. there is no radial gap between the outer edge ofthe air inlet 42 and the sidewall 41 and no axial gap between the bottomof the air inlet 42 and the end wall 40). Alternatively, the air inlet42 may be spaced radially inwardly from the sidewall 41 or axially abovethe end wall 40.

When combined with any other embodiment, the cyclone bin assembly 9 maybe of any particular design and may use any number of cyclone chambersand dirt collection chambers. The following is a description ofexemplified features of a cyclone bin assembly any of which may be usedeither individually or in any combination or sub-combination with anyother feature disclosed herein.

Screen

The following is a description of a cyclone and a screen that may beused by itself in any surface cleaning apparatus or in any combinationor sub-combination with any other feature or features disclosed herein.

Optionally, a screen or other type of filter member may be provided onthe cyclone air outlet 43 to help prevent fluff, lint and other debrisfrom exiting via the air outlet. Referring to FIG. 11, in theillustrated example a screen 50 is positioned at the air outlet 43 andconnected to the vortex finder 49. In FIG. 11 the screen is illustratedwith a representation of its mesh in place, however for clarity the meshhas been omitted from the other Figures. The screen 50 is generallycylindrical in the illustrated embodiment, but may be of any suitableshape, including for example frusto-conical, in other embodiments.Optionally, the screen 50 can be removable from the vortex finder 49.

Optionally, the screen 50 may be sized to have a cross-section area thatis larger than, smaller than or generally equal to the air outlet 43cross-sectional area. Referring to FIG. 13, in the illustrated example,the diameter 52 of the screen 50 is less than the diameter 51 of thevortex finder 49 conduit providing the cyclone air outlet 43. In thisconfiguration, the radial surface 53 of the screen 50 is radially offsetinwardly from the surface 54 of the vortex finder 49 by an offsetdistance 55. Providing the offset gap 55 between the surfaces 53, 54 ofthe screen 50 and vortex finder 49 may help provide a relatively calmerregion (i.e. a region of reduced air flow turbulence and/or laminar airflow) within the cyclone chamber 10. It may also assist the air that hasbeen treated in the cyclone chamber to travel towards the vortex finderwhile mixing less with the air entering the cyclone chamber via the airinlet and thereby reduce the likelihood of dirt bypassing treatment inthe cyclone chamber and travelling directly to the air outlet. Providinga relatively calmer air flow region adjacent the surface 53 of thescreen 50 may help enable air to more easily flow through the screen 50and into the vortex finder 49, which may help reduce backpressure in theair flow path. Reducing back pressure may help improve the efficiency ofthe cyclone chamber and/or may help reduce power requirements forgenerating and/or maintaining a desired level of suction.

In the illustrated embodiment the screen 50 is of generally constantdiameter. Alternatively, the diameter of the screen 50 may vary alongits length. For example, the screen may be generally tapered and maynarrow toward its upper end (i.e. the end that is spaced apart from thevortex finder 49). The cross sectional area of the inner end of thescreen may be 60-90% the cross sectional area of the air inlet andpreferably is 70-80% the cross sectional area of the air inlet.

The screen may be tapered such that the width at the base of the screen(adjacent the vortex finder) is greater than the width at the upper endof the screen. In this configuration the cross-sectional area of thescreen (in a plane that is generally perpendicular to the screen 50) isgreater at the base of the screen than at its upper end. The amount oftaper on the screen may be any suitable amount, and for example may beselected so that the cross-sectional area at the upper end of the screenis between about 60% and 90%, between about 70% and 80% and may be about63%-67% of the cross-sectional area of the base of the screen.

Dirt Outlet

The following is a description of a cyclone dirt outlet that may be usedby itself in any surface cleaning apparatus or in any combination orsub-combination with any other feature or features disclosed herein.

Cyclone chamber 10 may be in communication with a dirt collectionchamber by any suitable means. Preferably, as exemplified, the dirtcollection chamber 11 is exterior to cyclone chamber 10, and preferablyhas a sidewall 56 at least partially or completely laterally surroundsthe cyclone chamber 10. At least partially nesting the cyclone chamber10 within the dirt collection chamber 11 may help reduce the overallsize of the cyclone bin assembly. Referring to FIG. 2, in theillustrated embodiment the cyclone chamber sidewall 41 is coincidentwith the sidewall 56 for approximately half its circumference. It willbe appreciated that the dirt collection chamber may fully surround thecyclone chamber.

In the illustrated embodiment, the dirt outlet 44 is in communicationwith the cyclone chamber 10 and the dirt collection chamber 11.Optionally, the dirt outlet 44 can be axially and/or angularly spacedfrom the cyclone air inlet. Preferably, the cyclone dirt outlet 44 ispositioned toward the opposite end of the cyclone chamber 10 from thecyclone air inlet 42. The cyclone dirt outlet 44 may be any type ofopening and may be in communication with the dirt collection chamber toallow dirt and debris to exit the cyclone chamber 10 and enter the dirtcollection chamber 11.

In the illustrated example, the cyclone dirt outlet 44 is in the form ofa slot bounded by the cyclone side wall 41 and the upper cyclone endwall 39, and is located toward the upper end of the cyclone chamber 10.Alternatively, in other embodiments, the dirt outlet may be of any othersuitable configuration, and may be provided at another location in thecyclone chamber, including, for example as an annular gap between thesidewall and an end wall of the cyclone chamber or an arrestor plate orother suitable member. If the dirt outlet comprises an annular gap, thena cut out may be provided in the end of the sidewall of the cyclonechamber facing the end wall of the plate so that part of the sidewallmay be further from the plate or end wall than the rest of the sidewall.

In a preferred embodiment, a cyclone chamber comprises a uniflow cyclonewith a dirt outlet at the air outlet end. Preferably, the dirt outlet isa slot shaped dirt outlet and more preferably, the end wall abuts thesidewall of the cyclone chamber except at the location of the dirtoutlet. In such a case, the air outlet or vortex finder preferablyextends into the cyclone chamber further than the edge of the dirtoutlet that is spaced furthest from the end wall.

Referring to FIG. 13, the dirt slot 44 may be of any suitable length 57,generally measured in the axial direction, and may be between about 0.1inches and about 2 inches, or more. Optionally, the length 57 of theslot 44 may be constant along its width, or alternatively the length 57may vary along the width of the slot 44, preferably in the downstreamdirection as measured by the direction of air rotation in the cyclonechamber.

Optionally, the slot 44 may extend around the entire perimeter of thecyclone chamber (forming a generally continuous annular gap) or mayextend around only a portion of the cyclone chamber perimeter. Forexample, the slot may subtend an angle 73 (FIG. 10) that is betweenabout 5° and about 360°, and may be between about 5-150°, about 15-120°,about 35-75°, about 45 and about 90° and between about 60 and 80°.Similarly, the slot 44 may extend around about 10% to about 80% of thecyclone chamber perimeter, and preferably may extend around about 15% toabout 40% of the cyclone chamber perimeter.

Optionally, the slot 44 may be positioned so that it is angularlyaligned with the cyclone air inlet 42, or so that an angle 60 (FIG. 10)between the air inlet and the slot 44 (measured to a center line of theslot 44) is between about 0 and about 350° or more, and may be between5° and about 180° and may be between about 0 and about 90°. In someembodiments, the slot 44 can be positioned so that an upstream end ofthe slot (i.e. the end of the slot that is upstream relative to thedirection of the air circulating within the cyclone chamber) is betweenabout 0° and about 350° from the air inlet, and may be between about 5and 180° and between about 0-90°, about 0-45° and about 0-15° downstreamfrom the air inlet.

The dirt collection chamber 11 may be of any suitable configuration.Referring to FIG. 10, in the illustrated example, the dirt collectionchamber 11 includes a first end wall 61, a second end wall 62 and thesidewall 56 extending therebetween.

To help facilitate emptying the dirt collection chamber 11, one of orboth of the end walls 61, 62 may be openable. Similarly, one or both ofthe cyclone chamber end walls 39 and 40 may be openable to allow a userto empty debris from the cyclone chamber. In the illustrated example,the upper dirt chamber end wall 61 is integral with the upper cycloneend wall 39 and the lower dirt collection chamber end wall 62 isintegral with, and openable with, the lower cyclone chamber end wall 40and both form part of the openable bottom door 63. The door 63 ismoveable between a closed position (FIG. 11) and an open position (FIG.10). When the door 63 is open, both the cyclone chamber 10 and the dirtcollection chamber 11 can be emptied concurrently. Alternatively, theend walls of the dirt collection chamber 11 and the cyclone chamber 10need not be integral with each other, and the dirt collection chamber 11may be openable independently of the cyclone chamber 10.

Pre-Motor Filter Housing

The following is a description of a pre-motor filter housing that may beused by itself in any surface cleaning apparatus or in any combinationor sub-combination with any other feature or features disclosed herein.

Referring to FIG. 12, in the illustrated embodiment, the cyclone binassembly 9 includes a pre-motor filter chamber 31 that is positioned inthe air flow path between the cyclone chamber 10 and the suction motor 8(see also FIG. 11). One or more filters can be provided in the pre-motorfilter chamber 31 to filter the air exiting the cyclone bin assembly 9before it reaches the motor 8. Preferably, as exemplified, the pre-motorfilter includes a foam filter 32 and a downstream felt layer 33positioned within the pre-motor filter chamber 31. Preferably, thefilters 32, 33 are removable (FIG. 12) to allow a user to clean and/orreplace them when they are dirty.

Referring to FIG. 12, the pre-motor filter chamber 31 includes an upperend wall 110, a sidewall 111 and a lower end wall 112. Optionally, thesidewalls 111 of the pre-motor filter chamber 31 can be at leastpartially transparent so that a user can visually inspect the conditionof the filters 32, 33 to determine if they require cleaning orreplacement without having to remove the cyclone bin assembly 9.

The open headspace or header between the upper end wall 39 of thecyclone chamber 10 and the upstream side 123 of the filter 32 defines anupstream air plenum 124 (see FIG. 13). Providing the upstream plenum 124allows air to flow across the upstream side 123 of the filter 32. Theopen headspace or header downstream of the filters 32, 33, between thedownstream side 125 of filter 33 and the upper wall 110, provides adownstream air plenum 126. Providing a downstream plenum 126 allows airexiting the filters 32, 33 to flow radially across the downstream side125 of filter 33 and toward the pre-motor filter chamber air outlet 135.In use, air exits the cyclone chamber 10 via the air outlet 43 and flowsinto upstream plenum 124, through filters 32, 33, into downstream plenum126 and into the air outlet 135 of the pre-motor filter housing.

In the illustrated embodiment, the air outlet 135 is provided in the lid36 and has an inlet end 136 in the pre-motor filter chamber (FIG. 12)and an outlet end 137 provided on the outer surface of the cyclone binassembly (FIGS. 10 and 4). To provide air flow communication between thepre-motor filter chamber 31 and the suction motor 8, the outlet end 137is configured to mate with the inlet end 138 of a motor air flow passage139 provided in the surface cleaning unit 4. The motor air flow passage139 is in air flow communication with the air inlet 113 of the suctionmotor 8.

Referring to FIG. 12, most of the upper end wall 110 and sidewall 111may be provided by the inner surface of the lid 36, which may be openedto provide access to the filters 32, 32. In the illustrated embodiment,opening the lid 36 exposes the downstream side 125 of filter 33, whichis generally the cleaner side of the pre-motor filter. Configuring thepre-motor filter chamber so that the clean, downstream side of thefilter is exposed to the user when the lid 36 is opened allows a user tograsp the clean side 125 of the filter 33. This may allow the user toremove or manipulate the filter 33 while holding its clean side 125, andmay eliminate the need for a user to grasp or otherwise contact therelatively dirtier, upstream side of the filter.

Optionally, filter 33 may be connected to filter 32 so that a usergrasping the clean side 125 may be able to remove both filters 32, 33.Alternatively, the filter 33 may be removable independently from thefilter 32. In such a configuration, removing the filter 33 will exposethe downstream side 140 of the filter 32. While potentially not as clearas surface 125, the downstream side 140 of filter 32 is likely to becleaner than upstream side 123. In this configuration, a user can graspfilter 32 via downstream side 140 and can avoid having to touch orotherwise contact the dirtier upstream side 123.

Optionally, some or all of the intersections between the vortex finderand wall 110, the walls 110 and 111, the walls 111 and 112, and the wall112 and the pre-motor filter air outlet 135 may include angled or curvedsurfaces, for example like the surfaces within the cyclone chamber 10.Providing curved or smooth junctures within the pre-motor filter housing31 may help improve air flow and may reduce backpressure in the air flowpath. This may help improve the efficiency of the surface cleaningapparatus 1. Improving the efficiency may allow the surface cleaningapparatus to provide improved suction capabilities, and/or may allow thesurface cleaning apparatus to maintain its existing suction capabilitieswhile requiring a smaller, less powerful motor 8.

In the illustrated example, the bottom wall 112 includes a plurality ofsupporting ribs 130 that project upwards from the wall 112 into thechamber 31. The ribs 130 are configured to contact the upstream side 123of the filters (in this example felt filter 32) in the chamber 31 and tohold it above the wall 112, thereby help to maintaining the downstreamplenum 126. The ribs 130 are spaced apart from each other to allow airto flow between them, within the plenum 126, and toward the suctionmotor air inlet 113. In the illustrated embodiment, the upper wall 110also includes a plurality of ribs 130 for contacting the upstream side125 of the filters (in this example filter 33) and to maintain a spacingbetween the upstream side 125 and the wall 110 to provide the upstreamplenum 126.

Optionally, some or all of the support ribs in the pre-motor filterchamber 31 may be configured to help guide or direct the air flowingthrough the downstream plenum 126. For example, some of the ribs may beconfigured to help induce rotation of the air within the plenum 126,before it flows into the suction motor 8. Preferably, this pre-rotationof the air flow can be selected so that the air is rotated in thedirection of revolution of the suction motor 8. Pre-rotating the air inthis manner may help improve the efficiency of the surface cleaning unit4. The ribs may be configured in any suitable manner to help impartrotation to the air flow.

The ribs 130 define a rib height 133. If the lower wall 112 of thepre-motor filter is flat, the height 133 of each rib 130, 131 may remainconstant along its entire with. Alternatively, if the lower wall 112varies in height, (e.g., the ribs extend to a trumpet shaped portion ofa vortex finder, then the ribs 130, 131 may also vary in height so as toprovide a planar support surface for the filter. Preferably, the ribs130, 131 are configured such that the upper ends of the ribs 130, 131lie in a common plane to support the filter 33, and the lower ends ofthe ribs are in contact with the wall 112.

Pre-Motor Filter Dirt Chamber and Filter Cleaning Member

The following is a description of a pre-motor filter dirt chamber and afilter cleaning member, each of which may be used separately or togetherin any surface cleaning apparatus or in any combination orsub-combination with any other feature or features disclosed herein.

When the surface cleaning apparatus 1 is in use the upstream side 123 ofthe filter 32 may become soiled and/or partially blocked by dust andother relatively fine debris that is carried out of the cyclone chamber10. If the upstream side 123 of the filter 32 becomes sufficientlyblocked, air flow through filter 32 may be compromised and efficiency ofthe surface cleaning apparatus 1 may decrease. One method of cleaningthe upstream side 123 of the filter 32 is for a user to remove thefilter 32 as described above, clean the surface 123 and replace thefilter 32 within the pre-motor filter chamber 31. Optionally, instead ofcleaning the filter 32, a user may insert a new filter. Alternatively,instead of removing the filter 32 from the pre-motor filter chamber 31,the surface cleaning apparatus 1 may be configured to allow the filter32, particularly the upstream side 123, to be cleaned in situ, withoutremoving the filter 32 from the pre-motor filter chamber 31. Dirt anddebris may be extracted from the upstream side 123 using any suitablemechanism, including, for example, banging to tapping one or more sidesof the pre-motor filter chamber 31 and/or the pre-motor filter todislodge the dirt and using a mechanical and/or electro-mechanicalmechanism to help dislodge the debris. Examples of such mechanisms mayinclude, for example, a scraper or other mechanical member that contactsand cleans the surface 123 and a shaker or beater type of mechanism thatcan shake the filter 32 to help dislodge the debris.

Alternately, or in addition, the pre-motor filter chamber 31 may beconfigured to receive fine dirt and debris from the upstream side 123and direct the debris into a fine particle collection chamber orpre-motor filter dirt chamber that can collect the dislodged debris. Thefine particle collection chamber may be a portion of the primary dirtcollection chamber 11, or may be provided as a separate chamber. Thefine particle collection chamber may be positioned directly below theupstream side of the pre-motor filter so that dirt falls downwardly intothe chamber or it may be laterally spaced so that the dirt is conveyedlaterally, e.g., by a ramp or an angled surface, to the chamber.

Referring to FIG. 13, in the illustrated embodiment, the cyclone binassembly 9 includes a pre-motor filter dirt chamber 140 for receivingdebris 141 that is dislodged from the upstream upside 123 of filter 32.In the illustrated embodiment, the dirt chamber 140 is located withinthe extension member 77, which is inside the cyclone chamber 10. In thisconfiguration, there is no communication between the dirt chamber 140and the dirt chamber 11, nor do they share any walls or components incommon. Alternatively, the dirt chamber 140 may be nested within thedirt chamber 11 and/or may have one or more surfaces or walls in commonwith the dirt chamber 11.

In the illustrated example, the bottom wall 112 of the pre-motor filterchamber 31 (which is coincident with the upper wall 39 of the cyclonechamber 10 in this example) is curved downwardly toward the air inlet43. Curving the wall 112 in this manner may help guide the debris towardthe air outlet 43. When the air flow through the cyclone chamber 10 isoff (i.e. when the cyclone bin assembly 9 is removed and/or when thesurface cleaning apparatus is off), the debris 141 on wall 112 may falldownwardly though the vortex finder 39, through the air outlet, passthrough the interior of the screen 50 and fall into the dirt chamber140. Because the dirt chamber 140 is positioned below the air flowopenings in the screen 50 it may be a relatively low air flow regionwhen the surface cleaning apparatus is in use. This may allow debris 141that has accumulated in dirt chamber 140 to remain in the dirt chamber140 if the surface cleaning apparatus 1 is used prior to emptying thedirt chamber 140, as the debris 141 in chamber 140 will tend not to bere-entrained in the air flowing into the screen 50 and upwardly thoughthe air outlet 43.

The dirt chamber 140 includes a sidewall 142 and a bottom wall 143. Thetop of the chamber 140 is open to receive the debris 141. Referring toFIG. 10, in the illustrated embodiment the lower end of the dirt chamber140 is integral with the floor 40 of the cyclone chamber and is part ofthe openable door 63. In this configuration, the pre-motor filter dirtchamber 140 is contained within the cyclone bin assembly 9, and istherefore removable from the surface cleaning unit 4 with the cyclonechamber 10, dirt chamber 11 and pre-motor filter chamber 31 for emptyingand/or cleaning. Preferably, as illustrated, the dirt chamber 140 can beremoved in its closed configuration to help prevent dirt and debris fromspilling when the cyclone bin assembly 9 is manipulated.

In this configuration, opening the door 63 simultaneously opens thecyclone chamber 10, the dirt chamber 11 and the pre-motor filter dirtchamber 140. Alternatively, the pre-motor filter chamber 140 can beconfigured so that it is openable in combination with only one of thecyclone chamber 10 and/or dirt collection chamber 11, or independentlyfrom any other chamber.

For example, referring to FIG. 14 the cyclone bin assembly 9 can includea modified bottom door 63 that includes two separately openable portions63 a and 63 b that are pivotally mounted about hinge 63 c. Each doorportion 63 a, 63 b can be held closed by a corresponding, releasablelatch 151 a and 151 b (similar to latch 151 that holds the door 63closed). In this configuration, the dirt chamber 11 can be emptiedindependently of the cyclone chamber 10 and dirt chamber 140.

It will also be appreciated that the pre-motor filter chamber 140 may beremovable in combination with only one of the cyclone chamber 10 and/ordirt collection chamber 11, or independently from any other chamber.

Outwardly Biased Suction Hose

The following is a description of an outwardly biased suction hose and asuction hose chamber therefor, which may be used by itself or in anysurface cleaning apparatus or in any combination or sub-combination withany other feature or features disclosed herein.

Referring to FIG. 1, when a user is grasping the handle 17 to drive andmaneuver the surface cleaning head 3, the chassis portion 2 may bepulled along via hose 7. Typically, a hose is extensible and is biasedto a contracted position. If the portion of the hose 7 extending betweenthe handle 17 and the chassis portion 2 is elastic or otherwiseextensible it may be difficult for a user to accurately control themovement of the chassis portion 2. For example, for a user to advancethe chassis portion 2, the hose 7 would have to be stretched to itsmaximum length before a suitable pulling force would be transmitted tothe chassis portion 2.

Alternatively, the hose may be configured as a compressible hose that isbiased or sprung toward its extended configuration. The hose may includeany type of suitable biasing member, such as a spring. The biasingmember may be incorporated into the sidewall of the hose, or affixed tothe interior or exterior surface of the hose. Accordingly, in itsneutral state, the hose is extended and not contracted.

For storage and/or when the full length of the hose is not required forcleaning, the hose may be axially compressed into a retractedconfiguration (which may be at or close to its minimum length) within asuitable storage chamber, which may be part of a cord reel or part of asurface cleaning apparatus. The hose may be held in its compressed statewithin the storage chamber, which may help reduce the overall size ofthe surface cleaning apparatus. The hose may be held in place andcompressed using any suitable securement mechanism.

When the surface cleaning apparatus is in use a desired length of hosemay be metered out from the storage chamber by selectively releasing thesecurement mechanism and allowing the hose to spring or extend outwardfrom the chamber due to its internal biasing member. When a desiredlength of hose is exposed, the user may re-engage the securementmechanism to contain the remainder of the hose within the storagechamber.

Preferably, the hose is not further extensible beyond its extendedconfiguration. In this configuration, the exposed, uncompressed lengthof hose will not further stretch or extend when used to pull the chassisportion 2.

Referring to FIG. 15, another embodiment of a surface cleaning apparatus1001 is shown. The surface cleaning apparatus 1001 is generally similarto apparatus 1, and analogous features are identified using likereference characters indexed by 1000.

In this embodiment, the hose 1007 is a compressible hose that can becompressed from an extended length to a compressed or retracted length.Referring also to FIG. 16, the hose 1007 includes a biasing spring 1200within the hose sidewall 1201 that is configured to bias the hose 1007toward its extended length. The hose wall 1201 is preferably nototherwise extensible so that the hose 1007 generally cannot be stretchedbeyond its extended length. Optionally, in addition to a biasing spring1200, the sidewall 1201 may also include one or more electricalconductors, e.g. wires 1203, to transmit electrical power and/or controlsignals from the surface cleaning unit 4 to the handle 17, andoptionally downstream to the surface cleaning head 3 (for example topower a brush motor in the cleaning head 3).

In the illustrated embodiment, a hose storage chamber 1204 is providedas a portion of the up flow conduit 16, adjacent the handle 1017. Thehose storage chamber is configured to contain the compressed portions ofthe suction hose 1007, and preferably has a length 1205 that is betweenabout 50% and about 100% or more of the length of the hose 1007 in itsfully compressed state, so that the chamber 1204 is sized to containsubstantially all of the hose 1007 when it is compressed.

Referring also to FIG. 17, a schematic representation of the hosestorage chamber 1204 illustrates a compressed portion 1207 of the hose1007 contained within the storage chamber 1204, upstream from thesecurement mechanism 1208 which holds the hose 1007 in its compressedstate. An uncompressed or extended portion 1209 of the hose 1007 islocated outboard or downstream from the securement mechanism 1208 and,in the example illustrated, extends through the hollow interior 1210 ofhandle 1017.

In the illustrated embodiment, the securement mechanism 1208 includes apair of latch members 1211 that are pivotally mounted within the chamber1204 at pivot joints 1212. Each latch member 1211 includes an engagementend 1213 that frictionally engages the outer surface of the hose 1007 toprevent relative axial movement between the engagement ends 1213 and thehose 1007. When the latches 1211 are in their engaged position (FIG.17), the uncompressed portion 1210 of the hose 1007 is maintained at afixed length.

To allow additional hose 1007 to be drawn from the storage chamber 1204,the latch members 1211 may be disengaged by a user. In the illustratedembodiment, each latch member 1211 includes a contact portion 1214 thatcan be engaged by the user. Squeezing or otherwise depressing thecontact portions 1214 in the radial direction will cause the latchmembers 1211 to pivot about their respective pivot joints 1212 and willmove the engagement ends 1213 out of contact with the outer surface ofthe hose 1007. This will allow the compressed portion 1207 of the hose1007 to expand under its own biasing force, and to expand until thelatch members 1211 are re-engaged, or until the hose 1007 reachesmaximum length.

Preferably, the latch members 1211 are biased toward their engagedpositions, for example by springs 1215 so that the latch members 1211hold the hose 1007 in place until triggered by the user.

Optionally, the open end of the storage chamber 1204 can include one ormore guide members to help guide or direct the hose 1007 as it expandsoutwardly. This may help prevent kinks or other damage to the hose. Inthe illustrated embodiment, the storage chamber 1204 includes guidemembers in the form of rollers 1216 positioned toward the end of thechamber 1204, and outside the latch members 1211. The rollers 1216 mayrollingly contact the hose 1007 as it expands and may help prevent thehose 1007 from being curved or bent too tightly or from otherwisebecoming snagged to caught within the chamber 1204.

Optionally, the rollers 1216 may be dampened or otherwise configured sothat they provide a desired degree of rolling resistance when the hose1007 is expanding. Providing resistance with the rollers 1216 may absorbsome of the expansion force of the spring 1200, and may help control thespeed at which the hose 1007 expands from within the storage chamber1204. This may help prevent the hose 1007 from expanding more thandesired or from otherwise overwhelming the user when the latches 1211are disengaged. While illustrated as standalone rollers 1216, therollers 1216 may be connected to any suitable drive apparatus (such asan electric motor) to further control the expansion of the hose 1007.

When a user is finished with a given cleaning task, it may be desirableto re-compress the hose 1007 into the storage chamber 1204. In theillustrated embodiment, the latches 1211 are configured as one-waylatches so that when the hose 1007 is pushed inwardly (for example bythe user) the latches 1211 will automatically pivot or ratchet to allowthe hose 1007 to move freely inwardly (without needing to depress thecontact portions 1214), but will resist expansion of the hose 1007.Alternatively, instead of manually inserting the hose 1007, the hosestorage chamber 1204 may include an automated hose compression system.For example, in the illustrated embodiment the rollers 1216 may bepowered and may be operable to drive the hose 1007 into the storagechamber 1204. Alternately, rollers 1216 may be electrically driven andused without latch members 1211 or the like.

Optionally, instead of being provided on the up flow duct, the hosestorage chamber may be provided in the body of a surface cleaningapparatus, e.g., in a canister or base portion of the surface cleaningapparatus. Providing the hose storage chamber in the canister mayposition most of the weight of the hose within the canister (which rollsalong the ground during normal use) and may therefore help reduce theamount of weight that is carried directly by the user holding the handle17. In the illustrated example such a hose storage chamber could beprovided on the chassis portion 2 and/or the surface cleaning unit 4.

Referring to FIG. 18, a schematic example of a canister style vacuumcleaner 2001 is shown. The surface cleaning apparatus 2001 is generallysimilar to the apparatus 1, and analogous features are identified usinglike reference characters indexed by 2000. In this embodiment, thesurface cleaning unit 2004 is integral with the chassis portion 2002 toform the canister portion, and the hose storage chamber 2204 is providedwithin the canister portion.

Referring to FIG. 19, a schematic representation of an alternateembodiment of a hose storage chamber 3204 is shown. The hose storagechamber 3204 is generally similar to hose storage chamber 1204, andanalogous features are identified using like reference charactersindexed by 2000. In this embodiment, the securement mechanism 3208includes rollers 3217 instead of latches. The rollers 3217 each includeengagement projections 3218 for contacting and securing the hose 3007.The rollers 3217 are preferably driven using any suitable drivingmechanism (e.g. an electric motor and/or a spring that may be manuallywound) and can be used to drive the hose 3007 into the storage chamber3204 for storage. Optionally, the rollers 3217 need not be configured todrive the hose 3007 outward, and instead may simply be unlocked andallowed to rotate with the hose 3007 as it expands under its own biasingforce. Preferably, the rollers 3217 can be locked in place in order tohold the hose 3007 in a fixed position.

Surface Cleaning Unit with Onboard Energy Storage Device

The following is a description of an portable surface cleaning unit withan on board energy storage member and alternate configurations of abase, which may be used by itself or in any surface cleaning apparatusor in any combination or sub-combination with any other feature orfeatures disclosed herein.

Referring to FIG. 1, in the illustrated embodiment, the suction motor 8is provided within the surface cleaning unit 8. The electrical powercord 80 is, in this embodiment, connected to the surface cleaning unit 4and remains connected when the surface cleaning unit 4 is separated fromthe chassis 2 (FIG. 5) to supply power to the surface cleaning unit 4.In a first alternate embodiment, power cord 80 may be connected to thechassis portion 2 instead of directly to the surface cleaning unit 4. Inthis first alternate configuration, the surface cleaning unit 4 may beelectrically coupled to the chassis portion 2 when mounted on chassisportion 2.

According to this embodiment, surface cleaning unit 4 includes at leastone on board power supply or power storage device, which may comprise,for example, one or more of a battery, fuel cell and external combustionengine. In such configurations, the surface cleaning module may bepowered by AC power when docked, and powered by the on board powerstorage device when detached from the chassis portion. The suction motormay be configured to run on AC power when the surface cleaning unit 4 ismounted on the chassis. If the on board power supply provides DC power(such as a battery) the suction motor may also be operable to run on DCpower when the surface cleaning unit is detached (for example, thesuction motor may have dual windings).

Optionally, the chassis portion or the surface cleaning unit 4 mayinclude an electrical system for converting AC power to DC power(including, for example, a rectifier, inverter, transformer and othersuitable equipment) so that the suction motor in the surface cleaningunit may run on DC power when detached and when docked. This may allow asingle motor configuration to be used. Alternatively, the suction motormay be selected so that it is directly compatible with AC and DC powersources, such that a converter on the chassis portion to feed DC powerto the surface cleaning unit is not needed.

Preferably, the on board power storage device in the surface cleaningunit can be recharged, and more preferably can be recharged when thesurface cleaning unit is docked on the chassis portion. Optionally, thechassis portion can be configured to charge the surface cleaning unitwhile the suction motor is running (while the apparatus is in use),and/or while the suction motor is off (the apparatus is in storage).

In a second alternate embodiment, a different power cord 80 may beconnected to the chassis portion 2 in addition to the power cordconnected to the cleaning unit 4. In a third alternate embodiment, powercord 80 may be selectively connectable to the chassis portion 2 and thesurface cleaning unit 4. In this third alternate configuration, thesurface cleaning unit 4 may be electrically coupled to the chassisportion 2 when mounted on chassis portion 2 and power cord 80 isconnected to chassis 2 or power cord 80 may be directly connected to thesurface cleaning unit 4 and directly power the surface cleaning unit 4.

Referring to FIG. 20, another embodiment of a surface cleaning apparatus4001 and surface cleaning unit 4004 are shown. The surface cleaning unit4004 is shown with its upper cover cut-away and cyclone bin assemblyremoved. The surface cleaning unit 4001 is generally similar to surfacecleaning unit 1, and analogous features are illustrated using likereference characters indexed by 4000.

Referring to FIG. 21, in this embodiment, the electrical power cord 4008is connected to the chassis portion 4002, instead of the surfacecleaning unit 4004. To provide electrical communication, the chassisportion 4002 includes an electrical connector 4300 (preferably a femalesocket as exemplified) and the surface cleaning unit 4004 includes amating electrical connector 4301 (e.g., male prongs in the illustratedexample) that is mated with the connector 4300 when the surface cleaningunit 4004 is docked on the chassis portion 4002.

To power the surface cleaning unit 4004 when it is detached, in thisembodiment the surface cleaning unit 4004 includes an on board powerstorage device in the form of batteries 4302 (FIG. 20), which areelectrically connected to suction motor 4008. When the surface cleaningunit 4004 is detached from its chassis portion 4002 the suction motor4008 is powered by the batteries 4302.

In the illustrated example, the suction motor 4008 is a DC motor, andthe surface cleaning unit includes an on board converter module 4303 forconverting AC power from the cord 4080 into DC power suitable for themotor 4008. Preferably, the batteries 4302 can be rechargeablebatteries, and when the surface cleaning unit 4004 is docked, AC powerfrom the wall may be used to charge the batteries 4302. The convertermodule 4303 is also configured to allow the batteries 4302 to be chargedwhen the surface cleaning unit 4004 is connected to AC power. Theconverter module 4303 may include any suitable combination ofcomponents, including, for example, an inverter, a transformer and arectifier.

Alternate Power Modes

The following is a description of a portable surface cleaning unit withalternate power modes, which may be used by itself or in any surfacecleaning apparatus or in any combination or sub-combination with anyother feature or features disclosed herein.

Referring to FIG. 22, a schematic representation of the surface cleaningapparatus 4001 is shown. Optionally, a controller 4450 can be providedto alter the operation of the suction motor 4008 based on its powersupply. For example, when the controller senses that the surfacecleaning unit 4008 is being powered by an external power supply (e.g.,AC power via cord 4080) the suction motor 4008 can be operated at arelatively high power or “full power” mode. Alternatively, when thesurface cleaning unit 4004 is being powered by the on board powerstorage member (e.g. batteries and is being run on DC current), thecontroller may operate the motor 4008 at a relatively lower power level.Operating at a lower power level may help prolong the amount of cleaningtime that can be obtained using the on board batteries.

FIGS. 23 and 24 illustrate example embodiments of a converter module4303. Generally, converter module 4303 operates to convert AC signals toDC signals. The converter module 4303 may also transform an input powersignal to a signal suitable for the operation of the surface cleaningapparatus 4001. It will be understood that converter module 4303 may beprovided in one or more different configurations.

In FIG. 23, converter module 4303A includes an input terminal 4309, arectifier block 4310, a transformer block 4311 and output terminals4312, 4313. The input terminal 4309 receives an input AC signal 4314from the mating electrical connector 4301 and provides the input ACsignal 4314 to the rectifier block 4310 and the transformer block 4311.The rectifier block 4310 may include one or more electrical componentsfor converting the input AC signal 4314 to a rectified signal 4315. Forexample, the rectifier block 4310 can include one or more diodes invarious configurations as known in the art. The rectifier block 4310provides the rectified signal 4315 to the transformer block 4311.

In some embodiments, the rectifier block 4310 can also include a filteror a regulator for stabilizing a version of the rectified signal 4315prior to generating and providing the rectified signal 4315 to thetransformer block 4311.

The transformer block 4311 may include one or more electrical componentsfor varying the rectified signal 4315 to a signal suitable for theoperation of the surface cleaning apparatus 4001. For example, the inputpower signal 4314 received at the input terminal 4309 may be from thewall outlet and therefore, the value of the input power signal 4314 mayneed to be lowered. As illustrated in FIG. 23, the transformer block4311 is coupled to the two output terminals 4312, 4313. The transformerblock 4311 generates an output DC signal 4317 and an output AC signal4318, and then provides the output DC signal 4317 to the output terminal4312 and the output AC signal 4318 to the output terminal 4313.

As described above, the motor 4008 may be a motor that operates on ACpower or DC power. When the motor 4008 operates on AC power, the motor4008 can receive power via the output terminal 4313. Alternatively, whenthe motor 4008 operates on DC power, the motor 4008 can receive powervia the output terminal 4312. The batteries 4302 may also be charged viathe output terminal 4312. For example, the batteries 4302 may be chargedvia the output terminal 4312 while the surface cleaning apparatus 4001is docked on the surface cleaning unit 4. The batteries 4302 may becharged while the surface cleaning apparatus 4001 is in use or when thesurface cleaning apparatus 4001 is not in use.

In some embodiments, the converter module 4303 can include only oneoutput terminal, such as the output terminal 4312. Transformer block4311 can therefore generate and provide only one output signal, such asthe output DC signal 4317, to the output terminal 4312.

FIG. 24 illustrates a converter module 4303B. The transformer block 4311may be provided as two separate transformer blocks 4311A, 4311B. Similarto the transformer block 4311 of FIG. 24, the transformer block 4311Areceives the rectified signal 4315 from the rectifier block 4310.However, unlike the transformer block 4311 of FIG. 24, the transformerblock 4311A generates only the output DC signal 4317, which is thenprovided to the output terminal 4312. The transformer block 4311Breceives the input AC signal 4314 from the input terminal 4309 in orderto generate the output AC signal 4318.

It will be understood that the rectifier block 4310 and the transformerblock 4311 may be provided in a different order than as illustrated inconverter modules 4303A, 4303B. For example, the transformer block 4311may receive the input AC signal 4314 to generate a transformed signalwhich is either provided to the rectifier block 4310 for processingand/or directly to the output terminal 4313.

Electrical Cord Reel

The following is a description of an electrical cord reel, which may beused by itself or in any surface cleaning apparatus or in anycombination or sub-combination with any other feature or featuresdisclosed herein.

When the surface cleaning apparatus is not in use, it may be desirableto wind the electrical cord for storage. Optionally, a cord reel can beprovided to wind and hold the cord 80. The cord reel may be of anysuitable configuration and may be a manually actuated reel (for examplevia a hand crank) or an automated reel. If the reel is automated (i.e.can wind the cord without manual user intervention), it may be driven byany suitable mechanism including, for example, a spring, a biasingmechanism and/or a motor. The motor used may be an electric motor thatcan be operated at a speed that is suitable for winding the cord. If themotor is electric, preferably the cord reel is provided with a powersource (either on board or as part of the surface cleaning apparatus) sothat the cord reel motor can be powered even after the electrical cordhas been unplugged.

Optionally, the cord reel, and associated power sources, controllers,switches, etc. can be internal (i.e. inside one portion of the surfacecleaning apparatus) or external to the surface cleaning apparatus. Forexample, referring to FIG. 25, if the electrical cord 80 is connected tothe surface cleaning unit 4, any suitable cord reel (illustratedschematically as box 400) may be provided inside the surface cleaningunit 4. Alternatively, referring to FIG. 26 a, if the electrical cord4080 is attached to the chassis portion 4002, a cord reel 4400 can beprovided in the chassis portion 4002.

In one embodiment, cord reel 4400, may be configured to automaticallywind or unwind the cord based on at least one operating condition of thesurface cleaning apparatus. For example, the surface cleaning apparatusmay include a controller 4450 that is capable of sensing or detecting anoperating condition of the surface cleaning apparatus 4001 and thencontrol the cord reel based on the operating condition. Such a cord reelmay optionally, but need not, include any of the other features of acord reel disclosed herein

For example, referring to FIG. 26 b, a schematic representation of acord reel 4400 and a control system therefor is illustrated. While aschematic is illustrated, the control system may be of any suitableconfiguration. In the illustrated embodiment, the control systemincludes the controller 4450 (e.g. a PLC, microprocessor or onboardcomputer) that is communicably linked to the cord reel module 4400. Inthis configuration, the cord reel 4400 includes a motor 4424 to drivethe reel 4401 and an on board power supply in the form of batteries 4423to power the motor 4424. The controller 4450 is connected to control theoperation of the motor 4424.

One or more suitable sensors can be provided on the surface cleaningapparatus and connected to the controller 4450. In the illustratedexample, the control system includes a position sensor 4451 connected tothe controller. The position sensor 4451 can be any suitable type ofsensor that can detect the rate and direction of movement of the chassisportion 4002. For example, the sensor 4451 can be an encoder that canmeasure the speed and direction of rotation of the wheels 100, or may bean optical sensor that can determine movement by visually tracking thesurface under the chassis portion 2 or the rotation of a wheel of thechassis, or any other suitable sensor. In one embodiment, the controllercan be configured to determine when the vacuum cleaner is moving forwardand to unwind cord 80 from the reel 4401 at a given rate based on thespeed of the movement. Alternately or in addition, the controller may beconfigured to wind cord 80 onto the reel 4401 when the chassis portion4002 is moved backward. Alternatively, the sensor 4451 may be a receiver(e.g. a radio receiver) configured to receive external data, for examplefrom a transmitter positioned adjacent the wall. Using this signal, thecontroller may be able to determine the position of the chassis portion4002 relative to the transmitter and to unwind cord as the chassisportion 4002 moves farther from the transmitter and to wind the cord 80as the chassis portion 4002 moves closer to the transmitter. Such asystem may also be used in combination with a cord reel 400 that isprovided in the carryable surface cleaning unit 4, which may not havewheels or be in visual proximity to the ground.

An analogous control system, and or controller, may be included in otherportions of the surface cleaning apparatus, including, for example, inthe surface cleaning unit 4 or 4004, and optionally in the body orcontrol/drive module of an external cord reel.

In another embodiment, the cord reel may be a separate unit (i.e., itmay not be incorporated into the surface cleaning unit 4 or chassis) andmay have an on board energy storage member (e.g., one or morebatteries). Preferably, the batteries are charged when the cord reel isplugged into the wall. The cord reel may have a first short cord that isconfigured to plug into a household electrical outlet and a secondlonger cord that is configured to be plugged into the surface cleaningapparatus. Such a cord reel may optionally, but need not, include any ofthe other features of a cord reel disclosed herein.

For example, referring to FIG. 26 c, the cord reel 4400 may be separablefrom the chassis portion 4002 and may be configured as an external cordreel. In this configuration, the cord reel 4400 may be separated fromthe chassis portion 4002 and rested on the ground, for example adjacenta power socket. The cord 4080 can then be unwound from the reel 4400 asrequired to allow the chassis portion 4002 to be moved away from thewall socket. This may reduce the weight of the chassis portion 4002. Inthis embodiment, the controller 4450 may be located within the externalcord reel, instead of within the surface cleaning unit 4004 or chassisportion 4002. Optionally, the sensor 4451 can be a radio receiver andthe chassis portion 4002 can include a corresponding transmitter 4452 toallow the controller 4450 to determine the distance of the chassisportion 4002 from the cord reel 4400, and to unwind and/or wind cord 80as required.

Referring to FIG. 26 d, an analogous system can be used if an externalcord reel module 400 is connected to the surface cleaning unit 400,instead of the chassis portion 2.

In the illustrated example, the cord reel 400 may be a spring-poweredcord reel that can wind the cord using potential energy stored in aspring. To activate the cord reel, a user can press the cord reel button81 on the surface cleaning unit 4 to retract the cord 80. Alternatively,if the cord reel 400 were electrically driven, batteries could beprovided within the surface cleaning unit 4 (for example, similar to thebatteries 4302) to power the cord reel.

In another embodiment, the cord reel may be configured as a dual-windcord reel, in which the reel is positioned between the ends of the cordand winds the cord in two directions simultaneously (e.g. one revolutionof the reel winds two lengths of cord). Such a cord reel may optionally,but need not, include any of the other features of a cord reel disclosedherein

Optionally, the dual-wind cord reel may be configured so that itconnects to the cord without interrupting or forming part of theelectrical connection between the ends of the cord. In thisconfiguration, the cord reel need not include any type of rotatable orpivotal electrical connections, or any electrical connections at all,and may be referred to as a sealed or brushless cord reed. In thisconfiguration, the integrity of the electrical insulation of the cordremains intact, which may be desirable if used in wet or other hazardouslocations.

Referring to FIG. 27, an embodiment of a cord reel 401 that is suitablefor use with surface cleaning apparatus 1, 4001 and/or other surfacecleaning apparatuses is shown. The cord reel 401 includes a body 402that rotatably supports a reel member 403. The reel includes an innersidewall 403 that is rotatable about a reel axis 404. A central spindlemember 405 projects axially from the reel member 403 and rotates withthe inner sidewall 403. A handle 406 is provided toward the top of thebody 402 to allow a user to grasp and/or carry the cord reel 401 when itis separated from the surface cleaning apparatus.

In the illustrated embodiment, the cord reel 401 is configured to beattached to a portion of the cord 80 that is intermediate its two endsand preferably proximate the center of the power cord and, morepreferably, the reel 401 is connected to the middle of the cord 80.Connecting to the middle of the cord 80 may help ensure that the cord 80winds generally evenly around the spindle 405. Optionally, to helpretain the cord on the spindle 405 the reel 401 can include an outersidewall 407 that is connected to the free end 408 of the spindle 405.In the illustrated embodiment the outer sidewall 407 is detachable fromthe spindle 405. This may allow the cord 80 to be connected to the cordreel 401 and may help facilitate removal of the wound cord from thereel.

For example, in the illustrated embodiment, to attach the cord reel 401to the cord 80, the cord 80 is axially inserted into a slot 410 on thespindle 405. The slot 410 can be sized to receive a given cord 80, andmay extend along some, or substantially all of the length of the spindle405. Extending the slot 410 the entire length 411 of the spindle 405 mayallow the cord 80 to be positioned at any location along the spindlelength. Inserting the cord 80 axially into the slot 410 eliminates theneed to feed either end of the cord 80 through the slot 410 (or otherportions of the reel 401), which may allow for the slot 410 to be sizedto have a width 412 that is generally equal to the width 413 of the cord80.

Optionally, to help position the cord reel 401 in the middle of thelength of the cord 80, the cord 80 may be provided with a locatingmember identify the middle of the cord. Preferably, the locating memberis compatible with the cord reel 401 and more preferably, can fit withinor otherwise engage the spindle 405 (or other suitable portion of thecord reel 401).

Referring to FIG. 27 a, one example of a locating member is stripe 413provided on cord 80. The stripe 413 is visual indication of the middleof the cord 80, and a user may align the cord reel 410 with the cord 80by inserting the striped portion 413 into the slot 405. Optionally, thestripe 413 may be integral with the cord 80 (e.g. formed as adifferently colored portion of the cord 80 insulation, etc.) or may bepainted or otherwise marked on the outer surface of the cord 80. While astripe is illustrated, the visual indicator may be any suitable feature,including, for example, a sticker or wrapper, lettering or other words,a change in texture of the cord 80 surface, etc.

Optionally, instead of a visual indicator, the locating member may be aphysical object that is configured to engage or mate with the spindle405. For example, referring to FIGS. 28 a-c, instead of (or in additionto) a visual stripe 413, a locating member may be provided as an anchormember 413 a. In the illustrated example the anchor member 413 a is agenerally triangular member that is attached to the cord 80. The anchormember 413 a includes two mating halves 416 and 417 each of whichincludes a cord channel 418 extending therethrough. The halves 416, 417can be fastened together using any suitable mechanism, includingfasteners inserted into apertures 419, a snap fit or press fit and otherconnecting clamps or clips. Optionally, the anchor member 413 a can beprovided separately from the cord 80. This may allow a user to attachthe anchor member 413 a to any cord the user wishes to use incombination with the cord reel 401.

In the illustrated embodiment, in addition to the cord slot 410, thespindle 405 includes a central bore 418 that is configured to slidinglyreceive the anchor member 413 a. To accommodate the triangular anchormember 413 a, the bore 418 has three sides 119 a-c. In otherconfigurations, both the anchor member 413 a and bore 418 may have adifferent, corresponding shape, including, for example, square,pentagon, hexagon, etc. Referring to FIG. 33, the anchor member 413 a isshown inserted into bore 418. In this configuration, the anchor member413 a can also act as an alignment or keying member as it is configuredto fit into the bore 418 in an orientation such that the cord 80 alsopasses through slots 410.

In some configurations, when the spindle 405 is rotated faces 119 a-cmay engage and exert forces on corresponding faces on the anchor member413 a. This may help reduce the amount of force exerted directly on thecord 80 by the reel 401, which may help reduce cord damage.

Referring to FIG. 27 b, when the locating member (of any suitableconfiguration) is nested within the spindle 405, the outer sidewall 407can be attached (for example snapped in place or attached using clips orother suitable means) to secure the cord 80 on the reel 401. The spindle405 and sidewalls 403 and 407 can then be rotated using any suitablemeans to wind the cord 80 onto the reel 401. In the illustratedembodiment, both sides of the cord are drawn inwardly toward the reel401 and wrapped around the spindle 405.

Referring to FIG. 27 c, when the cord 80 is fully wound on the reel 401,both ends of the cord 80, female socket 414 and male prongs 415, can bepulled within the perimeter of the cord reel 401. In this embodiment,the prongs 415 are configured to connect to a standard wall socket, andthe socket 414 is configured to detachably connect to a correspondingport/coupling on the surface cleaning apparatus. Alternatively, thefemale end of the cord 80 may be fixedly connected to the surfacecleaning apparatus, and need not be detachable.

Referring to FIG. 27 d, to remove the cord 80 from the reel 401, theuser may unwind the reel or alternatively may remove outer sidewall 407and then axially slide the coiled cord 80 off of the spindle 405. Thismay allow a user to quickly remove the entire cord 80 from the reel 401without having to unwind its entire length.

The cord reel 401 may be driven (i.e. wound and/or unwound) using anysuitable mechanism, including for example a manual crank and a poweredmotor. Optionally, the reel 401 may include more than one drivingmechanism, which may allow the reel to be operated under a variety ofconditions.

Referring to FIG. 27 b, in the illustrated embodiment the cord reel 401includes a drive module 420 provided at the lower end of the body 402.In this configuration, the drive module 420 is generally opposite thehandle 406 and is positioned below the spindle 405. Preferably, thebottom surface 421 of the drive module 420 cooperates with the lowersurface 422 of the rest of the body 402 to provide a base for the cordreel 401. More preferably, the base is configured to support the cordreel in a generally upright position if/when it is placed on a flatsurface (such as the ground). This may allow the cord reel 401 to remainupright when detached from the surface cleaning apparatus and positionedon the ground.

The drive module 420 preferably includes an onboard energy storagemember in the form of batteries 423 and an electric drive motor 424. Thedrive motor 424 can be connected to the spindle 405 in any suitablemanner in order to drivingly rotate the spindle 405. In the illustratedembodiment, the perimeter of the inner sidewall 403 is provided with aplurality of gear teeth 425 which extend into the drive module 420.Inside the drive module 420, the motor 424 is connected to a drivingpinion or gear with teeth that mesh with the teeth on the sidewall 425.

A switch 425 is wired between the batteries 423 and the motor 424 tocontrol the operation of the motor 424, and the subsequent rotation ofthe spindle 405. The switch 425 may be any suitable type of switch, andin the example illustrated is a three-position switch. In thisconfiguration, the switch can be moved into a “wind” position in whichit causes the motor 424 and spindle 405 to rotate in one direction, an“unwind position” in which it causes the motor 424 and spindle 405 torotate in the opposite direction, and an off position in which the motor424 does not rotate. This may allow for powered winding and unwinding ofthe cord. Alternatively, or in addition, the drive mechanism may includea clutch or other suitable device so that in addition to being unwoundusing motor 424, the cord may be unwound simply by pulling on one orboth of its ends, and the spindle 405 is allowed to rotate in responseto such tension on the cord 80.

In addition to winding and unwinding, the motor 424 may be equipped witha torque sensor (e.g. current monitoring sensor) or other type ofcontroller that can disengage or deactivate the motor 424 if the tensionon the cord 80 exceeds a predetermined threshold (e.g. if the cord 80 isstuck or the 401 reel is jammed). This may help prevent damage to themotor 424, the cord 80 and the reel 401.

Preferably, if batteries are provided on board the cord reel, they arepreferably rechargeable. The batteries may be charged if the cord reel401 is connected to the body of the surface cleaning apparatus which hasan on board energy storage member, and/or by placing the drive module420 on an independent charging station or by connecting it to anexternal power source (e.g. a wall socket). Optionally, referring toFIG. 29, the drive module 420 may be removable from the body 402.Removing the drive module 420 may help reduce the overall size andweight of the cord reel 401. It may also allow the drive module 420 (ifit includes the batteries) to be charged separately from the cord reel401, and/or to be serviced or replaced with a different drive module420.

Referring to FIG. 30, as an alternative to the electric drive module 420or as a supplement thereto, the cord reel 401 may also include a manualdrive mechanism to wind the cord 80. This may be useful if the drivemodule 420 is removed and/or if the batteries 423 are dead. In theillustrated embodiment, the manual drive mechanism is provided in theform of a hand crank 425. The hand crank 425 includes a hand gripportion 426 and a linkage arm 427. The outer end 428 of the linkage armis connected to the hand grip 426 and the inner end 429 is connected tothe inner sidewall 403 and spindle 405. Rotating the hand crank 425winds and unwinds the cord 80. When not in use, the hand grip portion426 can be moved from a deployed position (FIG. 30) to a retractedposition (FIG. 31), which may help reduce the overall size of the cordreel 401. Reducing the size of the cord reel 401 may help facilitatestoring and/or mounting the cord reel 401 on a surface cleaningapparatus.

As exemplified in FIG. 32, the cord reel 401 may be configured to bemounted to, and carried on, the surface cleaning apparatus 1. Toaccommodate the external cord reel 401, the surface cleaning unit 4 mayinclude a reel mount 430 and the cord reel 401 may include acomplimentary mounting flange 431 provided on the back of the body 402(FIG. 30). The mounting flange 431 may be configured to fit within thecord mount 430 and can be held in place by gravity, and/or the use ofany suitable securing or locking members, including, latches, magnets,pins, detents, clips and other fasteners.

Preferably, in addition to providing a physical connection, the cordmount 430 and flange 431 can also include reciprocal electricalconnectors (e.g. a mating socket and prongs). In this configuration,when the cord reel 401 is docked on the surface cleaning unit 4, and thesurface cleaning unit 4 is powered (either by an external source or anon board source) the cord reel 401 can receive power from the surfacecleaning unit 4, or vice versa. This may allow the batteries 423 to becharged when the cord reel 401 is mounted on the surface cleaningapparatus 1. Alternately, the reciprocal electrical connectors may beused to power the surface cleaning unit when the power cord is pluggedinto an electrical outlet.

Optionally, the cord reel 401 may carry the only cord 80 provided withthe surface cleaning apparatus 1. In such a configuration, one end ofthe cord 80 is connectable to a port or connector on the surfacecleaning apparatus 1. Alternatively, the cord reel 401 may carry anadditional or supplemental cord 80, and the surface cleaning apparatus 1may include at least one internal cord reel as well. In such aconfiguration, the cord 80 on the cord reel 401 may function as anextension cord, and one end of the cord may be connected to the wallsocket while the other end of the cord is coupled to the free end of theelectrical cord that is integral the surface cleaning apparatus.

In the illustrated embodiment, mounting the cord reel 401 onto the backside of the surface cleaning unit 4 could potentially interfere with theair flow exiting the clean air outlet 6. To help facilitate air flow,the inner sidewall 403 and outer sidewall 407 are provided with aplurality of air flow apertures 432 to allow air to flow through thecord reel 401.

In an alternate embodiment, the cord reel could produce a DC output,such as by having an on board power supply.

Any of the features of the cord reels disclosed herein may be used withany other type of surface cleaning apparatus. The following descriptionexemplifies a number of the features of a cord reel disclosed herein inan upright-style surface cleaning apparatus. Referring to FIG. 34,another embodiment of an upright-style surface cleaning apparatus 5001is shown. Surface cleaning apparatus 5001 is generally similar tosurface cleaning apparatus 1, and analogous features are identifiedusing like reference characters indexed by 5000.

In this embodiment, the chassis portion 5002 is configured as the upperportion of the surface cleaning apparatus, and includes the rigid upflow duct 5016. In FIG. 34, the surface cleaning unit 5004 isillustrated including an optional internal cord reel 5400 that mayinclude any of the features of the cord reels described herein.Referring to FIG. 35, the surface cleaning apparatus 5001 is illustratedwith an external cord reel 5400 that includes a motor 5424, batteries5423, controller 5450, sensor 5451 and transmitter 5452 as describedherein. Optionally, some or all of these features may also be providedin the internal cord reel 5400 in FIG. 34. Preferably, the surfacecleaning unit 5004 is detachable from the chassis portion 5002, whichmay allow the user to reconfigure the surface cleaning apparatus 5001into a variety floor and above-floor cleaning modes.

Hand Carriable Surface Cleaning Apparatus

The following description exemplifies a number of the features disclosedherein in a hand carriable surface cleaning apparatus (e.g., a handvacuum cleaner, a pod vacuum cleaner or any other surface cleaningapparatus that may be carried by a handle or a shoulder strap or thelike). Referring to FIG. 37, another embodiment of a hand carriablesurface cleaning apparatus 10900 is shown.

The surface cleaning apparatus 10900 includes a main body 10901 having ahandle 10902, a dirty air inlet 10903, a clean air outlet 10904 (see forexample FIG. 26) and an air flow path extending therebetween. In theembodiment shown, the dirty air inlet 10903 is the inlet end ofconnector 10906. Optionally, the inlet end 10905 can be used to directlyclean a surface. Alternatively, the inlet end can be connected to thedownstream end of any suitable cleaning tool or accessory, including,for example a wand, a nozzle and a flexible suction hose.

The connector 10906 may be any suitable connector that is operable toconnect to, and preferably detachably connect to, a cleaning tool orother accessory. Optionally, in addition to provide an air flowconnection, the connector may also include an electrical connection10909 (FIG. 38). Providing an electrical connection 10909 may allowcleaning tools and accessories that are coupled to the connector 10906to be powered by the surface cleaning apparatus 10900. For example, thesurface cleaning unit 10900 can be used to provide both power andsuction to a surface cleaning head, or other suitable tool. In theillustrated embodiment, the connector 10909 includes an electricalcoupling in the form of a female socket member, and a corresponding maleprong member may be provided on the cleaning tools and/or accessories.Providing the female socket on the electrified side of the electricalcoupling may help prevent a user from inadvertently contacting theelectrical contacts.

Referring to FIG. 39, a construction technique that may be used byitself or with any other feature disclosed herein is exemplified. Inthis embodiment, the main body portion 10901 of the surface cleaningapparatus includes a core cleaning unit 11000 and an outer shell 11001.In the illustrated example, the core cleaning unit 11000 is a generally,self-contained functional unit that includes the dirty air inlet 10903,air treatment member 10910, pre-motor filter chamber 10956, suctionmotor 10911 and clean air outlet 10904. The outer shell includes matingside panels 11002, the handle portion 11003 of the surface cleaningapparatus (including the primary power switch 10985) and an openablepre-motor filter chamber cover 10959. When the outer shell 11001 isassembled around the core cleaning unit 11000 the exposed outer surfacesof the surface cleaning apparatus 10900 are formed from a combination ofportions of the core cleaning unit 11000 and the outer shell 11001. Forexample, the external suction motor housing 10912 and handle 10902 areprovided by the outer shell 11001, whereas the shell is shaped so thatportions of the cyclone bin assembly 10910 sidewalls remain visible inthe assembled configuration. If these portions are at least partiallytransparent, they can allow a user to see into the dirt collectionchamber 10914 to determine if the dirt collection chamber 10914 isgetting full.

From the dirty air inlet 10903, the air flow path extends through thecyclone bin assembly 10910 which forms part of the main body of thesurface cleaning apparatus. A suction motor 10911 (see FIG. 44) ismounted within a motor housing frame 11004 (FIG. 39) of the corecleaning unit 11000 and is in fluid communication with the cyclone binassembly 10910. In this configuration, the suction motor 10911 isdownstream from the cyclone bin assembly 10910 and the clean air outlet10904 is downstream from the suction motor 10911.

Referring to FIGS. 41 and 44, a uniflow cyclone and/or a cyclone withrounded junctures, and/or a cyclone with an insert member any of whichmay be used by itself or with any other feature disclosed herein isexemplified. In the illustrated embodiment, the cyclone bin assembly10910 includes a cyclone chamber 10913 and a dirt collection chamber10914. The dirt collection chamber 10914 comprises a sidewall 10915, afirst end wall 10916 and an opposing second end wall 10917. The dirtcollection chamber 10914 may be emptyable by any means known in the artand is preferably openable concurrently with the cyclone chamber 10913.Preferably, the second dirt collection chamber end wall 10917 ispivotally connected to the dirt collection chamber sidewall by hinge10919. The second dirt collection chamber end wall 10917 functions as anopenable door to empty the dirt collection chamber 10914 and can beopened (FIGS. 42 and 43) to empty dirt and debris from the interior ofthe dirt collection chamber 10914. The second dirt collection chamberend wall 10917 can be retained in the closed position by any means knownin the art, such as by a releasable latch 10919 a. In the illustratedexample, the hinge 10919 is provided on a back edge of the end wall10917 and the latch 10919 a is provided at the front of the end wall10917 so that the door swings backwardly when opened. Alternatively, thehinge 10919 and latch 10919 a may be in different positions, and thedoor 10917 may open in a different direction or manner. Optionally,instead of being openable, the end wall 10917 may be removable.

In the embodiment shown, the cyclone chamber 10913 extends along acyclone axis 10920 and is bounded by a sidewall 10921. The cyclonechamber 10913 includes an air inlet 10922 and an air outlet 10923 thatis in fluid connection downstream from the air inlet 10922 and one dirtoutlet 10924 in communication with the dirt collection chamber 10914. Inthis embodiment, the dirt collection chamber 10914 is positionedadjacent the cyclone chamber 10913 and at least partially surrounds thecyclone chamber 10913 in a side-by-side configuration.

Preferably, the air inlet 10922 is generally tangentially orientedrelative to the sidewall 10921, so that air entering the cyclone chamberwill tend to swirl and circulate within the cyclone chamber 10913,thereby dis-entraining dirt and debris from the air flow, before leavingthe chamber via the air outlet 10923. The air inlet 10922 extends alongan inlet axis 10925 that is generally perpendicular to the cyclone axis10920, and in the illustrated example is generally parallel to andoffset above the suction motor axis 10926.

In the illustrated example, the cyclone air outlet 10923 includes avortex finder 10927. Optionally, a screen 10928 can be positioned overthe vortex finder 10927 to help filter lint, fluff and other finedebris. Preferably, the screen 10928 can be removable.

The air inlet 10922 has an inlet diameter 10934, and a related inletflow cross-sectional area (measure in a plane perpendicular to the inletaxis). Preferably, the air outlet 10923 is sized so that the diameter10932 of the air outlet 10923, and therefore the corresponding flow areaof the air outlet 10923, is the same as the diameter of the air inlet.Alternatively, the air outlet diameter 10932 may be between about 50%and about 150%, and between about 85-115% of the air inlet diameter10925.

In the example illustrated the cyclone bin assembly 10910, and thecyclone chamber 10913 are arranged in a generally vertical, uniflowcyclone configuration. In a uniflow cyclone, the air inlet is locatedtoward one end of the cyclone chamber and the air outlet is providedtoward the other end of the cyclone chamber. In this configuration, airenters one end of the cyclone chamber and generally exits via the otherend of the cyclone chamber, as opposed to the cyclone chamberillustrated in the embodiment of FIGS. 1 to 18, in which air enters andexits the cyclone chamber via the same end. In the illustrated example,the air inlet 10922 is provided toward the lower end of the cyclonechamber 10913 and the air outlet 10923 is provided toward the upper endof the cyclone chamber 10913, such that air flows into the bottom of thecyclone chamber 10913 and exits at the top of the cyclone chamber 10913.Alternatively, the locations of the air inlet and outlet can bereversed.

Optionally, instead of a vertical configuration, the cyclone binassembly 10910 and cyclone chamber 10913 can be provided in anotherorientation, including, for example, as a horizontal cyclone.

Optionally, some or all of the cyclone sidewall 10921 can coincide withportions of the external sidewalls of the cyclone bin assembly 10910 andthe dirt collection chamber sidewall 10915. Referring to FIG. 51, in theillustrated embodiment the front portion of the cyclone chamber sidewall10921 is coincident with the outer sidewall of the cyclone bin assembly10910, and the rear portion of the cyclone sidewall 10921 helps separatethe cyclone chamber 10913 from the dirt collection chamber 10914. Thismay help reduce the overall size of the cyclone bin assembly 10910.Alternative, the sidewall 10921 may be distinct from the sidewalls10915. In alternative embodiments, the cyclone chamber 10913 may includeonly two dirt outlets 10924, or more than two dirt outlets.

In the illustrated embodiment, the cyclone chamber 10913 includes afirst or upper end wall 10937 (FIG. 51) and a second or lower end wall10943. The upper end wall 10937 is connected to the upper end of thesidewall 10921. In the illustrated example, a juncture 10938 between theend wall 10937 and the side wall 10921 is a relatively sharp corner thatdoes not include any type of angled or radiused surface. In contrast,the lower end wall 10943 meets the lower end of the cyclone sidewall10921 at a juncture 11005 that includes a curved juncture surface 11006(see also FIG. 45). The radius 11007 of the curved surface 11006 may beselected based on the radius of the air inlet (e.g. half of the diameter10934), and optionally may be the selected so that the juncture surface11006 has the same radius as the air inlet 10922.

The curved juncture surface can be provided as a portion of the sidewallor as a portion of the end wall. In the illustrated embodiment, thecurved juncture surface 11006 is provided as part of an insert member11008 that is provided on the bottom end wall and extends upward intothe interior of the cyclone chamber 10913. The insert member alsoincludes an upwardly extending projection member 11009 that extends intothe interior of the cyclone chamber and engages the distal end 10930 ofthe screen (FIG. 51). Together, the vortex finder 10927, screen 10928and projection member 11009 form a generally continuous internal columnmember that extends between the first and second end walls 10937 and10943 of the cyclone chamber 10910. Providing the projection member11009 may help direct air flow within the cyclone chamber, and may helpsupport and/or stabilize the distal end 10930 of the screen 10928.

Optionally, the juncture 11010 between the end wall 10943 and theprojection member 11009 may include a curved surface 11011 (see FIGS. 41and 44), and preferably is sized so that the surface 11011 has a radius11012 that is the same as radius 11007. Providing curved surfaces 11006and 11011 at the junctures between the end wall 10943 and the sidewall10921, may help reduce backpressure and may help improve cycloneefficiency. Preferably, the two curved juncture surfaces 11006 and 11011are separated by a generally flat, planar transition surface 11013,having a width 11014. Providing a flat transition surface 11013 may helpimprove air flow, and/or reduce back pressure to help improve cycloneefficiency.

In the illustrated embodiment, the second end wall 10943 of the cyclonechamber 10913, and the insert member 11008 provided thereon, is integralwith the openable bottom door 10917 that provides the bottom wall of thedirt collection chamber 10914. In this configuration, opening the doorsimultaneously opens the cyclone chamber 10913 and the dirt collectionchamber 10914 (see for example FIGS. 42 and 43) for emptying.

In the illustrated embodiment, the dirt outlet 10924 is in the form of aslot having bottom and side edges provided by the cyclone chambersidewall 10921, and a top edge provided by the upper end wall 10937.Alternatively, all four edges of the slot 10924 may be provided by thecyclone chamber sidewall 10921. The dirt slot 10924 is positioned at theback of the cyclone chamber 10921 and is generally opposite the airinlet 10922. In the illustrated embodiment, the upper wall 10937 of thecyclone chamber is integral with the upper wall 10916 (FIGS. 41 and 44)of the dirt collection chamber 10914.

Optionally, one or more pre-motor filters may be placed in the air flowpath between the cyclone bin assembly 10910 and the suction motor 10911.Alternatively, or in addition, one or more post-motor filters may beprovided downstream from the suction motor.

Referring to FIG. 45, a filter housing construction that may be used byitself or with any other feature disclosed herein is exemplified. In theillustrated embodiment a pre-motor filter chamber or housing 10956 isprovided between the upper walls 10937, 10916 of the cyclone 10913 anddirt collection chambers 10914 and the openable cover 10959. In thisconfiguration, the bottom wall 10957 of the pre-motor filter chamber10956 is integral with the upper walls 10937, 10916 of the cyclone 10913and dirt collection chambers 10914, and the upper wall 10958 a andsidewall 10958 of the pre-motor filter chamber 10956 are provided via afilter cartridge housing 11015 (see also FIG. 46). The filter cartridgehousing 11015 is separate from the openable cover 10959. One or morefilters may be positioned within the pre-motor filter chamber to filterfine particles from the air stream exiting the air outlet, before itflows into inlet of the suction motor. The filters may be of anysuitable configuration and formed from any suitable materials. In theillustrated embodiment, a foam filter 10960 and a felt filter 10961(FIG. 30) are positioned within the pre-motor filter chamber 10956.

Referring to FIGS. 45-48, the filter cartridge is a generally domeshaped member that includes an upper wall 10958 a and a sidewall 10958extending downwardly from the upper wall to surround the pre-motorfilters 10960, 10961. The pre-motor filters 10960, 10961 are shaped tofit within the cartridge member 11015, and when inserted within thecartridge member (FIG. 47) the downstream side 10965 of the felt filter10961 forms the bottom surface of the filter cartridge 11015. When thefilter cartridge 11015 is inserted in its use position (FIG. 46) thedownstream side 10965 of the pre-motor filter rests on the support ribs10962 (see FIG. 47) on the bottom wall 10957, and the downstreamheadspace 10964 (FIG. 45) is defined between the downstream side 10965of the filter 10961 and the bottom wall 10957.

In this embodiment, the upstream headspace 10970 (FIG. 35) is providedbetween the upstream side 10968 of the pre-motor filter 10960 and theupper wall 10958 a of the cartridge housing 11015 (instead of beingformed by the cover 10959). To provide air into the upstream headspace1970, the vortex finder 10927 projects upwardly from the bottom wall10957 and the filters 10960 and 10961 are provided with a correspondingaperture 10972 to receive the vortex finder 10927. Preferably, aplurality of spacing ribs 11016 (FIG. 48) are provided on the innersurface of the upper wall 10958 a to keep the upstream surface 10968 ofthe filter 10960 spaced apart from the inner surface of the upper wall10958 a to maintain the upstream headspace 10970.

The lower rim 11017 of the filter cartridge 11015 housing is configuredto seal against the bottom wall 10957 (for example via snap fit or byusing any type of suitable gasket or sealing member) to provide agenerally air tight pre-motor filter chamber 10956. The sealed chamber10956 is then covered by openable chamber cover 10959. As the filtercartridge housing 11015 provides a sufficiently air tight connection tothe bottom wall, the chamber cover 10959 need not be air tight.Preferably, at least a portion of both the chamber cover 10959 and thefilter cartridge 11015 housing is transparent so that a user can inspectthe upstream side 10968 of the pre-motor filter 10960 without having toremove it from the chamber 10956. Optionally, both the chamber cover10959 and filter cartridge housing 11015 may be formed from transparentplastic.

When a user wishes to remove, clean, change or otherwise access thepre-motor filter 10960, 10961 he/she may open the chamber cover 10959(FIG. 48) to expose the filter cartridge housing 11015. The user maythen detach the filter cartridge housing 11015 and separate it from thebottom wall 10957. Preferably, the pre-motor filters 10960, 10961 aresnugly received within the filter cartridge housing 11015 (or otherwiseretained therein) so that the filters 10960, 10961 are removed with thefilter cartridge housing 11015 and remain inside the filter cartridgehousing 11015 until removed by a user. In this embodiment, the dirty,upstream side 10968 of the filter 10960 remains enclosed by the filtercartridge housing 11015 when separated from the core cleaning unit11000, and only the relatively clearer downstream side 10965 of thefilter 10961 is exposed. This may help prevent dirt on the upstream side10968 of the filter 10960 from spilling or from otherwise contacting theuser. When at a desired location, for example at a trash receptacle or asink, a user can grasp the clean, downstream side 10965 of the filterand remove it from the filter cartridge housing 11015. The upstream side10968 of the filter can then be cleaned and inspected as desired.

To assist a user, the upper side 1958 a of the filter cartridge housing11015 may be provided with a grip member, for example the flange 11018in the illustrated embodiment (FIG. 46), which may allow a user tofirmly grasp and manipulate the filter cartridge housing 11015. The gripmember 11018 may be of any suitable configuration and optionally may beprovided on other portions of the filter cartridge housing (for exampleas a ridge or groove in the sidewall). Alternatively, the filtercartridge housing 11015 need not include a separate grip member.

To help reduce the overall size of the surface cleaning apparatus, inthe illustrated embodiment the pre-motor filter chamber 10956, and thefilters therein, is positioned above the cyclone chamber 10913 andcovers the upper end of the cyclone chamber 10913. In thisconfiguration, a plane 10966 (FIG. 44) containing the foam filter 10960is generally parallel and spaced above a plane 10977 containing the airoutlet 10923 of the cyclone chamber 10913, and both planes 10966, 10967are generally perpendicular to the cyclone axis 10920. Arranging thefilters 10960, 10961 in this configuration results in the upstream sideof the pre-motor filter (in this example the upper side 10968 of thefoam filter 10960) being spaced further apart from the cyclone chamber10913 than the downstream side of the pre-motor filter (in this examplethe lower surface 10965 of the felt filter 10961). Alternatively, inother embodiments, the pre-motor filter chamber 10956 may cover only aportion of the upper end of the cyclone chamber and/or may be laterallyspaced apart from the cyclone chamber.

When the surface cleaning apparatus is in use, air exiting the cyclonechamber 10913 can flow into the upstream head space 10970 via the vortexfinder 10927. Within the upstream headspace 10970 the air can flowlaterally across the upstream surface 10968 of the foam filter 10960,and down through the filters into the downstream head space 10964. Fromthe downstream head space 10964, the air can flow to the inlet 10973 ofthe suction motor via an internal air conduit 10974 (FIG. 44) formedwithin the body 10901. In the illustrated embodiment, the internal airconduit 10974 is formed within the main body 10901 and is external thecyclone chamber 10913 and the dirt collection chamber 10914 and ispartially bounded by an exterior surface exterior surface of the dirtcollection chamber sidewall 10915. The air conduit 10974 extendsgenerally vertically between the pre-motor filter chamber 10956 and thesuction motor 10911, and is positioned laterally intermediate thesuction motor 10911 and the cyclone chamber 10913. The suction motor10911 is positioned at an elevation where its air inlet 10973 isvertically between the upper and lower ends of the cyclone chamber10913, and the motor axis passes 10926 through the cyclone chamber 10913and the dirt collection chamber 10914.

Optionally, the cartridge member 11015 can be provided with a bottomcover 11030 to encase the filters 10960 and 10961 and to provide aself-contained pre-motor filter chamber 10956. Referring to FIGS. 51 and52, in such a configuration, the bottom cover 11030 may provide thebottom wall 10957 of the pre-motor filter chamber 10956, and may beprovided with internal ribs 10962 to support the filters 10960, 10961and to provide the downstream headspace 10964. An outlet port 11031provided in the bottom cover 11030 allows air to exit the cartridgeenclosure 11015 and flow into conduit 10974. Providing a sealedcartridge may help further contain dirt within the cartridge prior toemptying, and may help keep the filters 10960 and 10961 in position.

Referring to FIG. 38, in the illustrated embodiment, handle 10902 has afirst or bottom end 10981 that is adjacent the suction motor housing10912, a second or upper end 10982 that is spaced above from the lowerend 1981 and a grip portion 10980 extending therebetween. When graspingthe hand grip portion 10980, a user's fingers may pass through anopening 10984.

Referring to FIG. 49, a sectional view of an alternate embodimentcyclone bin assembly portion 12910 of a core cleaning unit 13000 thatmay be used by itself or with any other feature disclosed herein isexemplified. The cyclone bin assembly 12910 is similar to bin assembly10910, and like features are identified using like reference numeralsindexed by 2000. The cyclone bin assembly 12910 is illustrated inisolation with the outer shell, filter cartridge member and the suctionmotor removed. In this embodiment the cyclone chamber 12913 is flaredsuch that the cross-sectional area taken in a plane 13020 that passesthrough the air inlet 12922 (toward the bottom of the cyclone chamber12913) is smaller than the cross-sectional area taken in a plane 13021that passes through the dirt outlet 12924, and is smaller than thecross-section area of the upper end wall 12937 of the cyclone chamber12913 (which includes the air outlet 12923). In this configuration, thecyclone chamber sidewall 12921 includes a vertical portion 13022 and agenerally frusto-conical portion 13023 positioned above the verticalportion 13022. In this embodiment the volume of the cyclone chamber12913 increases toward the top to the cyclone chamber, which may helpimprove cyclone efficiency and/or may help dis-entrained dirt exit viathe dirt outlet.

Cyclone Bin Assembly

The following is a description of alternate cyclone bin assemblies,which may be used by itself or in any surface cleaning apparatus or inany combination or sub-combination with any other feature or featuresdisclosed herein.

Referring to FIG. 50, a sectional view of an alternate embodimentcyclone bin assembly 14910 portion of the core cleaning unit 15000 thatmay be used by itself or with any other feature disclosed herein isexemplified. The cyclone bin assembly 14910 is similar to cyclone binassembly 10910, and like elements are represented using analogousreference numbers indexed by 4000. The cyclone bin assembly 14910 isillustrated in isolation with the outer shell, filter cartridge memberand the suction motor removed. In this embodiment the cyclone chamber14913 is tapered such that the cross-sectional area taken in a plane15020 that passes through the air inlet 14922 (toward the bottom of thecyclone chamber 14913) is larger than the cross-sectional area taken ina plane 15021 that passes through the dirt outlet 14924, and is largerthan the cross-section area of the upper end wall 14937 of the cyclonechamber 14913 (which includes the air outlet 14923). In thisconfiguration, the cyclone chamber sidewall 14921 includes a verticalportion 15022 and a generally inwardly-tapering frusto-conical portion15023 positioned above the vertical portion. In this embodiment thevolume of the cyclone chamber 14913 decreases toward the top to thecyclone chamber, which may help improve cyclone efficiency and/or mayhelp dis-entrained dirt exit via the dirt outlet.

Referring to FIG. 53, a sectional view of an alternate embodimentcyclone bin assembly portion 16910 of a core cleaning unit 17000 thatmay be used by itself or with any other feature disclosed herein isexemplified. The cyclone bin assembly 16910 is similar to cyclone binassembly 10910, and like elements are represented using analogousreference numbers indexed by 6000. In this Figure, a pre-motor filterhousing construction that may be used by itself or with any otherfeature disclosed herein is exemplified.

In the illustrated embodiment, a pre-motor filter chamber or housing16956 is provided between the upper walls 16937, 16916 of the cycloneand dirt collection chambers 16913, 16914 and the openable cover (notshown). In this configuration, the bottom wall 16957 of the pre-motorfilter chamber 10956 is integral with the upper walls 10937, 10916 ofthe cyclone 10913 and dirt collection chambers 10914, and the upper wall10958 a and sidewall 10958 of the pre-motor filter chamber 10956 areprovided via a filter cartridge housing 17015. One or more filters maybe positioned within the pre-motor filter chamber to filter fineparticles from the air stream exiting the air outlet, before it flowsinto inlet of the suction motor. The filters may be of any suitableconfiguration and formed from any suitable materials. In the illustratedembodiment, a foam filter 16960 and a felt filter 16961 are positionedwithin the pre-motor filter chamber 16956.

The pre-motor filters 16960, 16961 are shaped to fit within thecartridge member 17015, and when inserted within the cartridge memberthe upstream side 16968 of the felt filter 16961 forms the bottomsurface of the filter cartridge 11015. When the filter cartridge 17015is inserted in its use position (as shown) the upstream side 16968 ofthe pre-motor filter rests on the support ribs 16962 on the bottom wall16957, and the upstream headspace 16970 is defined between the upstreamside 16968 of the filter 16960 and the bottom wall 16957.

In this embodiment, the downstream headspace 16964 is provided betweenthe downstream side 16965 of the pre-motor filter 16961 and the upperwall 10958 a of the cartridge housing 11015. Optionally, a plurality ofspacing ribs 17016 can be provided on the inner surface of the upperwall 16958 a to keep the downstream surface 16965 of the filter 16961spaced apart from the inner surface of the upper wall 16958 a tomaintain the downstream headspace 16964.

When the cyclone bin assembly 16910 is in use the upstream side 16968 ofthe filter 16960 may become soiled and/or partially blocked by dust andother relatively fine debris that is carried out of the cyclone chamber16913. If the upstream side 16968 becomes sufficiently blocked, airflowthrough the filter 16960 may be compromised and efficiency of thesurface cleaning apparatus may decrease.

One method of cleaning the upstream side 16968 of the filter 16960 isfor a user to remove the filter 16960 as described above, clean thesurface 16968 and replace the filter 16960 within the pre-motor filterchamber 16956. Alternatively, instead of removing the filter 16960 formthe pre-motor filter chamber 16956, the surface cyclone bin assembly16910 may be configured to allow the filter 16960, particularly theupstream side 16986, to be cleaned in situ, without removing the filter16960 from the pre-motor filter chamber 16956. Dirt and debris may beextracted from the upstream side 16968 using any suitable mechanism,including, for example, banging to tapping the sides of the pre-motorfilter chamber 16956 to dislodge the dirt and using a mechanical and/orelectro-mechanical mechanism to help dislodge the debris. Examples ofsuch mechanisms may include, for example, a scraper or other mechanicalmember that contacts and cleans the surface 16968 and a shaker or beatertype of mechanism that can shake the filter 16960 to help dislodge thedebris.

Optionally, the pre-motor filter chamber 16956 may be configured toreceive fine dirt and debris from the upstream side 16968 and direct thedebris into a fine particle collection chamber or pre-motor filter dirtchamber that can collect the dislodged debris. The fine particlecollection chamber may be a portion of the primary dirt collectionchamber 16914, or may be provided as a separate chamber.

In the illustrated embodiment, the cyclone bin assembly 16910 includes atwo pre-motor filter dirt chambers 17040 a and 17040 b for receivingdebris 17041 that is dislodged from the upstream upside 16968 of filter16960. In the illustrated embodiment, the first dirt chamber 17040 a islocated within an extension member 17042, which is inside the cyclonechamber 16913. In this configuration, there is no communication betweenthe first dirt chamber 117040 a and the dirt chamber 16914, nor do theyshare any walls or components in common.

The second dirt chamber 17040 b is provided outside and adjacent thedirt chamber. The second dirt chamber 17040 b is partially bounded bythe sidewall 16915 of the primary dirt collection chamber 16914, but isexternal the chamber 16914 and includes a sidewall 17043. The seconddirt collection chamber 17040 b has a bottom wall 17044 that ispivotally connected to the cyclone bin assembly 16910. The bottom wall17044 can be opened and closed independently of the bottom walls 16917and 16943 of the dirt collection chamber 16914 and cyclone chamber 16913respectively.

In the illustrated example, the bottom wall 16957 of the pre-motorfilter chamber 16956 (which is coincident with the upper wall 39 of thecyclone chamber 10 in this example) is inclined from left to right asillustrated. Sloping the wall 16957 in this manner may help guide thedebris 17041 that falls from the left side of the filter 16960 (asillustrated) toward the air outlet 16923, and may guide debris that ispositioned to the right of the air outlet 16923 (as illustrated) towardto second dirt chamber 17040 b. When the air flow through the cyclonechamber 16913 is off (i.e. when the cyclone bin assembly 16910 isremoved and/or when the surface cleaning apparatus is off), some of thedebris 17041 may fall downwardly though the vortex finder 16927, throughair outlet 16923, pass through the interior of the screen 16928 and fallinto the dirt chamber 17040 a. Because the dirt chamber 17040 a ispositioned below the air flow openings in the screen 16928 it may be arelatively low air flow region when the surface cleaning apparatus is inuse. This may allow debris 17041 that has accumulated dirt chamber 17041to remain in the dirt chamber 17040 a if the surface cleaning apparatusis used prior to emptying the dirt chamber 17040 a, as it is unlikelythat the debris 17041 will be re-entrained in the air flowing into thescreen 16928 and upwardly though the air outlet 16923.

Similarly, in the absence of strong air flow, some of the debris 17041may collect at the bottom of dirt chamber 17040 b. Like chamber 17040 a,chamber 17040 b is provided below and generally outside the primary airflow path through the cyclone bin assembly 16910. This may allow debris17041 to remain contained in dirt chamber 17040 b if the cyclone binassembly 16910 is operated before emptying dirt chamber 17040 b.

The dirt chamber 17040 a includes a sidewall 17046 and a bottom wall17047. The top of the chamber 17040 a is open to receive the debris17041. In the illustrated embodiment the bottom wall 17047 of the dirtchamber 17040 a is a cap member that is distinct from the floor 16943 ofthe cyclone chamber 16913. In this configuration, opening the door 16943simultaneously opens the cyclone chamber 16913, the dirt chamber 16914but does not automatically open the pre-motor filter dirt chamber 17040a. To empty the dirt chamber 17040 a, the user can remove the bottomwall 17047. This allows a user to decide when to empty the dirt chamber17040 a independently from the cyclone chamber 16913 and the dirtchamber 16914. Alternatively, the dirt chamber 17040 a need not includea separate bottom wall member 17047, and the bottom of the dirt chamber17040 a can be sealed by the bottom wall 16943 of the cyclone chamber16913. In such a configuration, the dirt chamber 17040 a would be openedwith the cyclone chamber 16913. The bottom wall 17044 is not operativelyconnected to the bottom walls 16917 and 16943, and therefore chamber17040 b is openable independently from dirt chamber 17040 a, cyclonechamber 16913 and dirt chamber 16914.

Optionally, the cyclone bin assembly 16910 may include an additionaldirt collection chamber that is positioned within the pre-motor filterchamber 16956. Referring to FIG. 54, the cyclone bin assembly 16910 isillustrated containing a removable dirt collection chamber 17040 cpositioned within the pre-motor filter chamber 16956. The dirtcollection chamber 17040 c is a cup-like member that can collect aportion of the debris 17041 that falls from the filter 16960. Providinga third chamber 17040 c may help reduce the amount of debris thataccumulates within chambers 7040 a and 17040 b. In the illustratedconfiguration, the dirt chamber 17040 c is not emptyable like chambers17040 a and 17040 b and does not include any type of openable door.Instead, the dirt chamber 17040 c is removably seated within thepre-motor filter chamber 16956 and can be removed for emptying when thefilters 16960 and 16961 are removed by the user.

In these examples, debris 17041 may be dislodged from the filter 16960by shaking or banging the cyclone bin assembly 16910. Alternatively, afilter cleaning mechanism can be included within the pre-motor filterchamber 16956.

Referring to FIG. 55, another embodiment of a cyclone bin assembly 18910is exemplified having an example of a filter cleaning mechanism 19060,which may be used in combination with any other suitable cyclone binassembly described herein. In the illustrated embodiment, the filtercleaning mechanism 19060 is provided in the form of a rotating sweeperapparatus 19061 that includes a pair of sweeper arms 19062 that canscrape the upstream surface 18968 of the filter 18960. The sweeper arms19062 may be of any suitable configuration, and may be formed from anysuitable material including, for example, plastic and metal.

The sweeper arms 19062 are connected to a central hub 19063 which ismounted to shaft 19064. Shaft 19065 is driven by electric motor 19065and rotates about axis 19066. The motor 19065 is mounted to one of thesupport ribs 18962 within the upstream head space 18970. Additional ribssurrounding the filter cleaning mechanism 19060 may include cut-outs toallow the sweeper arms 19062 to pass. Alternatively, instead ofcompleting full revolutions the motor 19065 may be configured tooscillate back and forth.

Providing the filter cleaning mechanism in the upstream headspace 18970may be advantageous as it allows the sweeper arms 19062 to directlyengage the upstream surface 18968.

The motor 19065 may be supplied with power from any suitable source,including the external power source and/or an onboard power storagedevice, such as batteries. Providing batteries may be advantageous as itmay allow the filter cleaning mechanism 19069 to be operated when thesurface cleaning apparatus is unplugged.

Alternatively, instead of providing a motor 19065, the shaft 19064 maybe rotatably or pivotally supported by bearings or bushings within thepre-motor filter chamber 18956, but need not have a drive mechanism. Insuch a configuration, the sweeper arms 19062 may be moved across thesurface 18968 of the filter 18960 when a user shakes or bangs theoutside of the cyclone bin assembly 18910. In this configuration, thefilter cleaning mechanism 19060 may amplify the user's input force anduse that force to clean the filter 18960. In yet another alternativeconfiguration, an external crank or actuator may be provided to allow auser to manually rotate the shaft 19064 and sweeper arms 19062.

Also of note in this embodiment, the bottom walls 19044 and 19047 of thepre-motor filter dirt chambers 19070 b and 19070 a are both integralwith walls 18917 and 18943. In this configuration, the pre-motor filterchambers 19040 a and 19040 b, the cyclone chamber 18913 and dirt chamber18914 are simultaneously openable.

Referring to FIG. 56, the cyclone bin assembly 18910 is illustratedcontaining another embodiment of a filter cleaning mechanism 19060,which may be used in isolation or in combination with any other featuresherein. In this embodiment, the filter cleaning mechanism 19060 includesa motor 19065 that is mounted to the upper wall 18958 of the cartridgehousing 19015 and is positioned within the downstream headspace 18964.The motor 19065 includes an output shaft 19064 that is coupled to aneccentrically mounted beating member 19070. The beating member 19070 canbe formed from any suitable material (e.g. plastic and metal) and can beof any suitable shape.

In the illustrated embodiment the beating member is a generallycylindrical member mounted eccentrically on the shaft 19064. As theshaft rotates the beating member 19070 will periodically impact thedownstream side 18965 of filter 18961. The impact on the surface offilter 18961 may produce vibrations in filter 18961, and the vibrationsmay be transferred to filter 18960. Vibrations in filter 18960 may tendto dislodge debris from the upstream side 18968 of the filter 18960, andinto the dirt collection chambers 194040 a and 19040 b. The motor 19065may be powered using any suitable source as described herein.

What has been described above has been intended to be illustrative ofthe invention and non-limiting and it will be understood by personsskilled in the art that other variants and modifications may be madewithout departing from the scope of the invention as defined in theclaims appended hereto. The scope of the claims should not be limited bythe preferred embodiments and examples, but should be given the broadestinterpretation consistent with the description as a whole.

What is claimed is:
 1. A surface cleaning apparatus comprising: a) abody housing a suction motor; b) a uniflow cyclone chamber comprising afirst end having a first end wall, a second opposed end having a secondend wall, a sidewall, an air inlet in the first end, a dirt outlet inthe second end and an air outlet that is configured so that air exitsthe cyclone chamber through the second end; c) a dirt collection chamberexterior to the cyclone chamber; and, d) an air flow path extending froma dirty air inlet to a clean air outlet and including the suction motorand the cyclone chamber.
 2. The surface cleaning apparatus of claim 1wherein the cyclone chamber has a longitudinal axis and the dirt outletis oriented generally parallel to the longitudinal axis.
 3. The surfacecleaning apparatus of claim 1 wherein the sidewall extends to the secondend and the dirt outlet is provided in the sidewall.
 4. The surfacecleaning apparatus of claim 1 wherein the first end comprises a lowerend.
 5. The surface cleaning apparatus of claim 1 wherein the dirtoutlet has a radial extent and has an upstream end and a downstream endbased on the direction of airflow in the cyclone chamber and theupstream end is located from 0-90° downstream from the air inlet.
 6. Thesurface cleaning apparatus of claim 5 wherein the upstream end islocated from 0-45° downstream from the air inlet.
 7. The surfacecleaning apparatus of claim 5 wherein the upstream end is located from0-15° downstream from the air inlet.
 8. The surface cleaning apparatusof claim 5 wherein the downstream end is located from 5-150° downstreamfrom the upstream end.
 9. The surface cleaning apparatus of claim 6wherein the downstream end is located from 15-120° downstream from theupstream end.
 10. The surface cleaning apparatus of claim 7 wherein thedownstream end is located from 35-75° downstream from the upstream end.11. The surface cleaning apparatus of claim 1 wherein the dirt outlethas a radial extent and has an upstream end and a downstream end basedon the direction of airflow in the cyclone chamber and the downstreamend is located from 5-150° downstream from the upstream end.
 12. Thesurface cleaning apparatus of claim 11 wherein the downstream end islocated from 15-120° downstream from the upstream end.
 13. The surfacecleaning apparatus of claim 11 wherein the downstream end is locatedfrom 35-75° downstream from the upstream end.
 14. The surface cleaningapparatus of claim 1 wherein the dirt collection chamber partiallysurrounds the cyclone chamber.
 15. The surface cleaning apparatus ofclaim 14 wherein the dirt outlet has a radial extent and has an upstreamend and a downstream end based on the direction of airflow in thecyclone chamber and the upstream end is located proximate a location atwhich a sidewall of the dirt collection chamber extends outwardly fromthe sidewall of the cyclone chamber.
 16. The surface cleaning apparatusof claim 5 wherein the dirt collection chamber partially surrounds thecyclone chamber and the upstream end is located proximate a location atwhich a sidewall of the dirt collection chamber extends outwardly fromthe sidewall of the cyclone chamber.
 17. The surface cleaning apparatusof claim 11 wherein the dirt collection chamber partially surrounds thecyclone chamber and the upstream end is located proximate a location atwhich a sidewall of the dirt collection chamber extends outwardly fromthe sidewall of the cyclone chamber.
 18. The surface cleaning apparatusof claim 13 wherein the dirt collection chamber partially surrounds thecyclone chamber and the upstream end is located proximate a location atwhich a sidewall of the dirt collection chamber extends outwardly fromthe sidewall of the cyclone chamber.
 19. The surface cleaning apparatusof claim 1 wherein the dirt collection chamber surrounds the cyclonechamber, the dirt outlet has a radial extent and has an upstream end anda downstream end based on the direction of airflow in the cyclonechamber and the upstream end is located from 0-90° upstream from alocation at which a sidewall of the dirt collection chamber is closestto the sidewall of the cyclone chamber.
 20. The surface cleaningapparatus of claim 19 wherein the upstream end is located proximate thelocation at which a sidewall of the dirt collection chamber is closestto the sidewall of the cyclone chamber.